Service Manual LIEBHERR D 904 / 906 D 914/916 D 924 / 926Foreword ‘This manual includes the major points for proper maintenance, adjustments and repairs with technical data and screw tightening torques for Liebherr Diesel engine D 904 / 906 / 914 / 916 / 924 / 926. ‘These tasks must be carried out by trained professionals, ‘The Service manual will not be updated. For that reason, we always refer to additional Service Information bulletins, All changes will be incorporated when the Service manual is reissued periodically No part of this documentation may be reproduced or copied without our explicit writen permission, ‘This Service manual was written by Liebherr-Machines-Bulle S.A., Dept. Service - Diesel - Engine and issued by the Service Dept, Liebherr Hydraulikbagger GmbH, Kirchdorfilller, Dept. VS. ‘All changes reserved LIEBHERR-MACHINES-BULLE SA All rights reserved. Dept.: Service ~ Diesel - Engine Issue: 1d. No. 12/2003 8718458 (English)Index Engine illustrations Technical description Engine description, engine data tag, cylinder description, direction of rotation and engine identification number Engine data, adjustment values, operating pressures, operating temperatures and fluid quantities Torque specifications Valve adjustment Cylinder head gaskets Cylinder head Cylinder liner Piston and connecting rod Check piston clearance Crankshaft an bearing Camshaft and valve drive Lubrication circuit Oil pans Lube oil pump Lube oil fitter and oil cooler Coolant circuit Water fiter Coolant pump Fan drive Fuel system Fuel pump Fuel filter Injection pump Injection pump drive, adjust begin of delivery Fuel injector Engine exhaust Fan and flywheel side crankshaft seal Hydraulic pump auxilary drive Air compressor Starter Air conditioner compressor and alternator Starting aid Turbo charger Gear drive Maintenance and inspection Service fluids Troubleshooting Special toolsEngine illustrations Engine view: Left, as seen from the flywheel side onto the engine 4 Air compressor 2 Oil separator 3 V-belt - crankshaft 4 Coolant temperature sensor 5 Oil pressure sensor (with warning contact) 6 Starter 7 Coolant pump 8 Fan 9 Alternator 40 Coolant thermostat 41 Exhaust turbocharger 12 Water filter 13 Air conditioner compressor Engine view: Right, as seen from the flywheel side onto the engine 14 Oil dipstick 15 Valve cover 16 Oil filter 17 Injection pump 18 Oil filler neck 49 Suction pipe 20 Fuel filter 21 Fuel pump 22 Solenoid valve (flame glow plug) 23 Flame glow plug 24 ~~ Data tag 25 Hydraulic pump aD904/ 914/924 D906 / 916/926 Date 42/2003Technical description Engine design Water-cooled, 4 and 6 cyinder in-line engines with LIEBHERR direct injection processand exhaust turbocharger. Characteristics Asturdy basic construction and generous dimensions provide the foundation for high operating ‘safety and long service lie. Low fuel consumption, low noise and exhaust emissions are achieved through a combustion process, which is specially adapted to requirements. Low maintenance effort on easily accessible components and a variety of optional accessories ensure good overall efficiency. Power transmission ‘The 4 cylinder engines feature a steel crankshaft with 5 bearings, the 6 cylinder engines 7 bearings, with inductively hardened bearing surfaces and 8 / 12 forged counterweights. A vibration damper is installed on the fan side on the crankshaft. Forge-pressed, split connecting ‘od, leaded bronze tri-metal sliding bearings or sputter bearings, smooth shaft three ring piston ‘of aluminum alloy with ring support and combustion recess in the piston base. Exchangeable, wet cylinder liners Housing ‘The crankcase is made inone unit of alloy cast iron. Single oyinder heads with integrated intake channel and removable / exchangeable vale seat rings and valve guides. Flywheel housing, front timing case and oil pan on the underside close off the engine. Engine timing Per cylinder one intake ard exhaust valve each, suspended in the cylinder head (ohv.). ‘Actuated by a steel camshaft with 5 or 7 bearings via steel tappets, push rod and rocker arm. Drive of camshaft, injection pump, lube oil pump, air compressor, coolant pump, and auxiliary hydraulic pumps by the crankshaft via nitride gears on the fan Lubrication Force-feed lubrication with gear pump for crankshaft, connecting rod and camshaft bearings as well as piston pin bushing, tappet and rocker arm, Oil filtration via two replaceable filter elements in the main cil circuit. Auxiliary components as ‘well as injection pump and air compressor are comected to engine lubrication circuit. The engine oil cooler is integrated in the coolant flow. Cooling Dual thermostatically regulated fluid cooling with retary pump. Individual supply of each oylinder unit va distributorchannels integrated in the crankcase. Piston cooling through oil spray from engine lubrication circuit Fuel injection system and regulation Maintenance free BOSCH in line injection pump or distributor pump with mechanical BOSCH centrifugal regulator. On _A4, AS - engines with ,EDC” control (electronic regulation), fue! pump with fuel fier, BOSCH four or six hole nozzles.Flame starter ‘The fiame starter is a cold starting assistance for bw ambient temperature. It minimizes the emission of white smoke after starting the diesel engine. By reducing the starting period, the starter and the batleries vill be saved. “The flame spark plug, mounted in the air intake, will get fuel via a solenoid valve with dosaging nozzle and could set free. Electrical equipment Starter and atternator: 24 Volt Electronic sensors controlling the engine parameters Air charge pressure sensor, temperature sensor at cooling agent and air charge, rotation sensor and ol pressure sensor are indicators for the external contro! functions. Each function and error signal is descrited in the corresponding user manual. Benennung / Description / D 9041 914/924 D 906/916 /926 Datum / Edition? Technical description Date 12/2003Cross section ‘Benennung / Description / P model D 924/926 TT-E Datum / Edition / 12/2003 Technical descriptionLength section ‘Benennung /Deserbtion/ * UEBHERR wns rei) D928 TITLE Datum’ Eaton? Technical description Tyee Date Blatt 24 4212003 Fase3 Engine description, engine data tag, cylinder description, direction of rotation and engine identification number Engine description: 5 904 T - E A1—_ Version Emission optimized Additional | Addition Diesel engine | Year Bore Stroke No. of mm. mm cylinders Inline engine 90. 415, 135 46 ot. 120 135, AIG _| 92. 422 442 a6 ‘Additional identification: NA = naturally aspirated engine, TB = ,moderately* turbo- charged engine, T = Turbo-charged engine, TI= Turbo-charged and inter-cooled Version: 1 = Distributor type injection pump ‘A2_ = MW-P3000- injection pump 3. = P7100- injection pump Ad =P7100+“EDC"(slectronic regulation) ‘AS =H-RP43- Control-sieeve injection pump + EDC (Electronic regulation) Engine data tag: ‘The engine data tag is installed on the right side of the crankcase, as seen from the flywheel, above the injection pump. On some engine versians, an additional second data tag is installed on the air intake pipe. Data: Type 9147, D926TI etc. Mot. Nr. Engine number Code = Inspection (performance) number ww Performance in KW ‘min. ‘Nominal engine RPM Ucferumfang = —_—Id. No. of engines In addition, the engine performance standard is noted in the lower leftfield. Additional data tag: For additional data, an additional data tag may be installed . Data: Code = _ Inspection (performance) number Field 1 = EU member number Field 2. = Inspection number per ECE regulation R2t or Rag Field 33. = Approval numberEngine data tag MOT.NR Afin TEFERUNEANG , Additional data tag CODE © LIEBHERR © 'Benennung / Desorption / Engine description, data tag, cylinder description, turning direcfon and engine identification number Te. 1D 90479141924 Model D906 / 916 / 926 ‘Type Bat Foulle34 Engine description, engine data tag, cylinder description, direction of rotation, and engine identification number Engine data tag for ,E“ (emission optimized) engines from 1997: Note: ‘The text on the engine data tags on the engines isin English. For clarification, the text is translated in German for the Service Manual Cylinder description, direction of rotation: Cylinder 1 is located on the flywheel side. The cyinder numbers are cast into the upper side of the crankcase when viewed from the flywheel, asis the firing order. The direction of rotation is to the left, viewed from the flywheel. Engine number: ‘The engine number is engraved into the data tag and in the crankcase. The engine number is ‘on the crankcase, on the left hand side on the lop after the last cylinder, as seen from the flywheel 2003 1 0050 Year cylinder running number 02 = 6 cylinder Engine number - examplTMPORTANT ENGINE INFORMATION ENGINE EE —— ENGINE DISPLACEMENT (CTERST RUECTION THONG (DEGREES BTDC) FUEL RATE (CUBIC mn/STRONE), TARE VALVE Sitar) Ld 2 ere | one Sone commas wares on | E—— Sommenon cmavpienese.eue | CS | Retkonccwwewere Lo |) AH CALIFCRONA IS Soxeesimaon FEGULATION FOR NaOAD | Bena one Conteeceron ete vOn ENONES ( UEBHERRIACHINES BULLE S.A. MADE WN SWITZERLAND Engine data tag Cylinder description ‘Turning direction ‘Benannung / Description ! Denomination Engine description, data tag, cylinder description, turning direction and engine identification number Tye, 0D 904/914/ 924 Tye D906 / 916 / 826 12/2003Engine data: D 904 / 906 Working procedure: : Four cycle Diesel engine Combustion procedure: Direct injection Bore 2 115mm Stroke 2 135mm Total volume : D904 = 56dm* D906 = 84dm* (1.4dm? per cyl.) Nominal RPM 2000, 2100 4/min. Compression ratio > D9O4NA/TB = 17.071 D906NA/TB =~ 17.0:1 D904T = 15.5:4 D906 T = 15.5: D906 TI = 18.5:4 Firing order 2 4Cyl 1-3-4-2 6 Cyl. 1-5-3-6-2-4 Firing distance in °KW 4Cyl = 180-180 - 180-180 = 720 6Cyl = 120-120-120-120-120-120=720 ‘Benennung / Description / Engine data, adjustment values, operating pressures, atu aiton ‘operating temperatures and fluid quantities Date 12/2003Adjustment values: Begin of delivery in °KWv. OT — : D 904 NA/ TB, D 906 NA/TB D 904 T, D 906 T/T! ( RQV-Regulator) 1D 904 T, D 906 T/ TI( RSV-Regulator) Valve play intake cold 2mm Exhaust cold =0.25mm Operating pressures: ‘Compression pressure D904 NA/ TB, D 908 NA/ TB D904 T,D 906 T/TI Injection pressure D 904 NA/ TB, D 906 NA/ TB ~New = 260+ ° bar - Operating pr. = 252+ * bar D 904 T, D 906 T/T! |RQV-Regulator) -New 225+ ° bar ~ Operating pr. 217+° bar 0 904 T, D906 T/T! |RSV-Reguiator) - New 260+® bar = Operating pr. = 252+ ® bar Minimum lube oil pressures at engine operating temperature: at nominal RPM =3.5bar at 1400 ‘min =2.5 bar at 800 ‘imin = 1.5 bar Minimum pressure in cooling system with engine at opereting temperature: at nominal RPM = 1.1 bar (thermostats open) measured onthe coolant pump outlet Operating temperatures: Coolant temperature, maximum + 100°C Thermostats - opening temperature 71°C, 79 °C, 83°C Lube oil temperature, maximum 115°C Oil quantities: Lube ollin oil pan 4 cyl =maximin 16/101 Gcyl =maximin 20/101 dependingon cil 225/121 pan version Marks on dipstick are the determining factor. ‘Benennung / Description / Engine data, adjustment values, operating pressures, operating temperatures and oll quantities 1212003Engine data : D 914/916 Working procedure : Four cycle Diesel engine Combustion procedure : Direct injection Bore : 4120 mm Stroke Total volume D916 =9.2 dn? (1.525 dm® per cyl.) Nominal RPM : 1800, 2000, 2100 ‘/min Compression ratio :D914T/TI=15.9:1 D916 T/TI=15.9:1 Firing order roy =1-3-4-2 6 cyl. =1-5-3-6-2-4 Firing distance in ° KW : 4 oyl. = 180 - 180 - 180 - 180 = 720 6 cyl, = 120 - 120 - 120 - 120 - 120 - 120 = 720 Ye D918/ 916 ‘Benennung / Description Denomination Engine data, adjustment values, operating pressures, 21 2003. ‘operating temperatures and oil quantitiesAdjustment values: Begin of delivery in ° KW v. OT pots =2081 poet n= 1800 / 2100 "/min #2021 peteT n= 1800 ‘/min = 2024 DoeT/T n= 2000 min 2224 DoeT! 2100 "Imin = 1521 valve play Intake cold = = 0,2 mm Outletcold = 0,25 mm Operating pressures: Compression pressure D914T/TI =19-27 bar DO1eT/TI =19-27 bar Injection pressure New = 225+ 8 bar Operating pressure = 217+ 8 bar Lube oil pressures with atnominal RPM = 3.5 bar ‘engine at operating temperature at 1400 “/min = 2.5 bar at 800 'imin = 1.5 bar Minimum pressure in cooling system with engine at operating temperature: at nominal RPM (thermostats open), measured onthe coolant pump outlet Operating temperatures: Coolant temperature, maximum 100°C Thermostats opening temperature: 71°C, 79°C, 83°C Lube oil temperature, maximum 115°C Oil quantities: Lube oil in olf pan 4cy=mex/min 16/401 6oyl.=max/min 20/101 Depending cn 22,51 121 type of oll pan Marks on dipstickare the determining factor. ‘Bonennung//Descripfon / Denomination Typ Dots 916 Model Type Engine data, adjustment values, operating pressures, Date Eaition ‘operating temperatures and oll quantities Date 12/2003 43 FoulEngine data: D 926 TI Working procedure : Four cycle Diesel engine Combustion procedure : Direct injection Bore 2122 mm Stroke 2142 mm Total volume 9.96 dm (1,66 dm’ per cyl.) Nominal RPM : 1800, 2000, 2100 ‘min Compression ratio 21654 Firing order 14-5-3-6-2-4 Firing distance in = KW 2120 - 120 - 120 - 120 - 120 - 120 = 720° ;Benennung / Description / Denomination Engine data, adjustment values, operating pressures, Datum {Edition {Date operating temperatures and oil quantities 12/2003Adjustment values: Begin of delivery in ° KW v. OT n= 1800/2000 min =2021° n= 2400'%nin 161° Valve play Intake cold = 0.2mm Exhaust cold = 0.25 mm Operating pressures: Compression pressure 19-27 bar Injection pressure New = 225+ 8 bar Operating pressure =217 +8 bar Minimum lube oil pressure with engine at operating temperature: at nominal RPM = 3,6 bar at 1400 “min 2.5 bar at 800 “/min = 1,5 bar Min. pressure in cooling system with engine at operating temperature: at nominal pressure = 1,1 bar Engine (thermostats open) measured on coolant pump ext Operating temperatures: Coolant temperature, maximum 100°C Thermostats opening temperature 2 TA°C, 79°C, 83°C Max. Lube oil temperature 115°C Oil quantities: Lube oi in oll pan max! min 20/101 } Depending on 22.5121 type of cil pan The mark on the dipstick is the deciding factor. yp. D926 TI ‘Benennung / Description / Modet Engine data, adjustment values, operating pressures, ‘operating temperatures and oil quantities Datum / Edition / Date 12/2003 45 FeuilleEngine data: D924 T-E/ TIE D926 T-E/ TI-E Working procedure Four cycle Diesel engine Combustion procedure _: Direct injection Bore 2122 mm Stroke 2142 mm Total volume D924 T-E/ TLE = 6,64 dm D 926T-E / TI-E = 9,96 dm® (1,66 dm* per cyl.) Nominal RPM 1500, 1800, 2000, 2100 ‘min Compression ratio 20924 T-E/TLE 17,221 D926T-E/THE= 17,2:1 Firing order shoyl=1-3-4-2 Boyl.=1-5-3-6-2-4 Firing distance in® KW: 4 cyl. = 180 - 180 -1B0 -180 = 720° B cyl. = 120 - 120 - 120 - 120 -120 - 120 = 720° DOMTE! THE Model D926 T-E/ TIE Engine data, adjustment values, operating pressures, operating temperatures and oil quantitiesAdjustment values: Begin of delivery in °KW v. OT or in mm for VE- injection pump Valve play Operating pressures: Compression pressure Injection pressure Min. lube oil pressures with engine at operating temperatue: at nominal RPM For data, see engine data tag By AS-engines is the delivery beginin degress crank angle according to OT (= upper death point) Intake cold 0.25 mm Exhaust cold 0.30 mm 0924 T-E/ TLE D926 TE /TLE New Operating pressure at 1400 “min at 800 "min Min, pressure in cooling system with engine at operating temperature: at nominal RPM = 1.1 bar (thermostats open) measured on coolant pump outlet Operating temperatures: Coolant temperature, maximum Thermostat opening temperature Lube oil temperature, maximum Oil quantities: Lube oil in oi! pan 4 cyl. = maximin 6 cyl, = maximin Benennung / Deserption / Datum / Edition Dato 42/2003 Engine data, adjustment values, operating pressures, ‘operating temperatures and oil quantities 400°C 71°C, 79°C, 83°C 118°C 20,5/13,51 20/101 } Depending on type of 2251121 oil pan. ‘Mark on dipstick is the deciding factor Typ D924 T-E/ THE Mocs! 926 T-E/ TLE ‘Type Feuille.For Description uence Pa ‘Torque specifications ‘ann dete, ‘see page Cylinder head bolts pretension Nm 30° 30+ 30+ 60 + 60= 180 78 soft cylinder head gasket Retighten cylinder head bolts | “90 78 soft Cylinder head gasket jon Nm 30 Nm90+ “70+ 70+ 70 + 70= 280 Cylinder head bolts pretensi 78 Metallic elastomer- Cyinder head gasket ‘Screws for rocker M10 x 65 M10 x 110 (ZBS) ‘arm suppert Nm 65 Nm 75 13 ‘Connecting rod screws pretension Nm 30°45 + 30+ 30= 105 10 ‘Main bearing screws pretension Nm 30 =°30+30+30=90 12 pretension Nm 30 Mi4x1,5x50 =" 30+ 35=65 29 Flywheel screws Nm 180 - 330 = 330 M16 x 1,5 x 50 pretension Nm ©0 Mi6 x 1,5 130 7° 30+ 90+ 40 = 100 Nm 180 - 330 = 330 Timing case screws. pretensionNm 30 Wi2x55 = 30 Nm 80 pretensionNm 45 12x65 =" 30 Nm 110 M12x 140%" 80 Nm 110 ‘Screws for fan side pretension Nm 30 12x 1,5x 160 =" 45 + 45 = 90 Nm 100-160 = 160 29 crankshaft end M16 x 1,5 x 160" 40 + 30+ 30= 100 Nm 100-300 = 300 ‘Screw on intermediate gear | pretensionNm 60 = 70 Nm 280 > pretension M 16x15 Nm60 #60 s chant Nm 280 on camshal gear pretension M 20x 1,5. Nm 130. "105 Nm 650 Serew am camshaft gear wn | Protension M 16 x1.5Nm 60 60 ger for fan drive hm 280 pretension M 20x 4,5Nm 130 2°405 Nm 650 ‘Banennuna / serotion / Danemination Torque specification Typ 0908/9141 924 Model 90 / 916 / 926For sequence Description Torque specifications ‘and data, see page Nut on injection pump drive} pretension Nm 30 Nm 300 26 ‘Screw for gear injection pump ° ave (drive mounted in ming | e*ension Nm 30 40 261/282 case) Nm 110 pretension Nm 30 Nm 250 ‘Screws for intermediate flange 263 ‘on hub injection pump drive pretension Nm 30 Nm 61 ‘Screws for intermediate flange 263 ‘on gear wheel injection pump . drive Nut for gear shaft on injection | yep HRPAS pump HR 25 W14x1,5 M18K15 — M20x15 M24x1,5 Nm 85*® Nm too" = Nm 150° Nm 355 Injector mount Nm 23 a Union nut for fue nj D 904/ 906/ 914/ 916/ 926T_D 924 / 926T-E/TLE om hum 50” Nm 4"? Injection fines Nm 20 Piston cooing nozzle 10 Nm 30 Screw forcoolant pump gear | pretension Nm 30 ¥ 90 x0 Nm 115 Nut on coolant pump impeller Nm 100 20 pretension Nm 30 ‘Screw for coolant pump hub 20 Nm 115 ‘Nat for coolant pump impelier |~* 3.17202 (coolant pump integrated in | pretension Nm 30 Nm 70° 20.3/20.4 timing case) Typ Mosel ‘Type 904/914 /:924 9061916 / 926Visco and fan coupling (2 Description Torque specifications For sequence and data, see page Screw for coolant pump gear | * (coolant pump integrated in 2011202 timing case) pretension Nm 30. Nm 70" 203 ‘Screw fer coolant pump . mounting (coolant pump 2011202 integrated in timing case) Nm 15 203 Screw (lube oil nozzte) for . coolant pump mounting, mounted with collar bearing | Nm 20 204, 20.5 ‘Screw for gear fan drive pretension Nm 30 0 a Nm 120 pretension Nm 30 M18 1,580 Screw for hub on fan drive 24.21213/21.4/21.5 Nm 270 ‘Screw for hub on fan drive with | pretension Nm 30 M18 x1,5x 140 fan coupling (2 speed) 212/213 Nm 270 ‘Screw for hub on fan drive with | pretension Nm 20 M16x15x 110] 949 )04.3/214 Nm 90-140 = 140 M12x 90 Nm 70-110 = 110 M16x 1,5x 160 Nm 300 speed) Nm 270 ‘Screw for hub on fan drive with M16x1,5x 160 fan coupling (3 speed) 2223 Nm 180 ‘Screw for V-belt on crankshaft |prefension Nm 30M12x 45%" 30+ 15= 45 20 ‘Screws for Exhaust manifold ‘on cylinder head Mgx80 Nm 36 atim /Edltion / Date 42/2003 ‘Benennung / Description / Denomination Typ Mode! Type ‘Torque specification D 9041 914/924 D 906/916 /926For sequence and Description | Torque specifications data, see page iLucas) (Bosch) 5/818 UNF-2A 5/8-1BUNF-2A M 14x 1,5 Nut for V-belt on alternator | 4m 54°? Nm 1028” Nmas* 3 16x15 M24x15 M27x1,5 Nm 503° Nm 1352" Nm 155+"* M18x1,5 M20x1,5 M20x1,5 Nat fora compressr (sw= 30mm) (SW=27 mm) at Nm 80s"? Nm 150 Nm 200 Nut for gear on hydraulic pump Nm 50"? Two hole nut on the . 302 hydraulic pump drive (drive | pretension Nm 30 Nm 300 controllable) — Two hole nut on the . 308 hydraulic pump drive pretension Nm 30_Nm240 Screw for Dayco-roler_| Pretensionm 20° M10x50__Nm 48 33.3 * Screw retaining fluid =Loctite 243 Screw retaining fluid =Loctite 262 ‘Screw retaining fluid = Loctite 222 ‘+ Screw retaining fluid = Loctite 270 D 90419147 924 ne D906 1916/9268 ‘Benennung / Description / Denomination Torque specification ‘turn / Eaton jaue speci Date 12/2003Torque specifications For screws according to DIN 912, 931, 933, 960, 961 Permissible tolerance + 10 % ‘Surface condition: Screw Mn or Zn phosphated, not lubricated or oiled 11 ges. = 0,14 Regular | 8,8 10,9 12,9 Fine 88 10,9 129 threads | Nm Nm Nm threads | Nm Nm Nm M6 10 18 18 MBxt 27 30 46 MB 25 6 43 mioc,25 | 52 78 90 M10 49 2 & miaxt25 | 93 135 160 M12 85 125 145 | [txts 89 130 155 Mia 136 200 235 M141 5 145 215 255 M16 210 310 365 MAGC1,5 225 330 390 M16 300 430 500 | [texts 340 485 570 20 425 610 710 | [201.5 475 680 790 M22 580 820 960 | [azact.s 630 900 41050 M24 730 1050 1220 | [zea 800 1150 1350 Surface condition: Screws galvanized, not lubricated or oled 1 ges. = 0.125 Ms 96 14 16 Mex! 25 37 43 ue 23 34 40 mioct25 | 49 71 83 M10 48 87 73 M12c1,25 87 130 150 M12 79 115 135 M1215, 83 120 145 Mi4 125 185 220 M1415, 135 200 236 M16 195 290 340 M1615 210 310 360 MiB 280 400 470 Mia 5 315 450 530 M20, 395 560 660 M2015 440 630 730 M22 540 760 890 M2215 590 840 980 M24 680 970 7150 | [M2aa2 740 1050 4250 1D 904/914 /924 Modo! Mode 1p 906/ 916 / 926Valve adjustment Valve play: D 904/906 / 914/916 / 926 TI intake cold = 0.20 mm Exhaust cold = 0.25 mm D 924/926 T-E/TI-E Intake cold = 0.25 mm Exhaust cold = 0.30 mm Valves of cylinder D904/914/924 D906 / 916/926 overlap adjust Overlap adjust 4 1 6 1 2 3 2 5 1 4 4 3E = Inlet valve A= Outlet vaive LEEREENEERER | 00070! Overton Oonominaton TP. D804 / 914/924 net D906 / 916/926 ecu Eton Oote Valve adjustment Biot 421200364 Valve adjustment Engine auxiliary brake system (ZBS) Function ,ZBS“ for engine brake operation: If the engine brake fiap is closed, pressure waves are building up in the exhaust pipe, which cause the outet valve to ,reopen. The outiet vale is reopened for a short time every time the flap closes. Due to the fact that the piston is under pressure, itis ,pushed after" the opening outet valve, but cannot retum, since the adjustment screw 1 closes off the relief bore 6 ad the check valve in piston 5 closes off the oil supply bore. ‘This causes the outlet valve to remain open by about 1.5 to 2 mm during the compression stroke and the subsequent expansion cycle (downward movement of the piston). Check the valve clearance: Inlet valve: Check as without ,2BS* Outlet valve: Tum the crankshaft until the valves opposite the cylinder, which is to be adjusted overlap (see chart, page 6). Push the rocker lever with a screwdriver several times onto the valve in the area of piston § Until no more oll escapes from the relief bore 6. Insert a feeler gauge between the outlet valve and piston 5 and check the valve clearance. Adjust the valve clearan Inlet valve: Adjust as without ,ZBS" Outlet valve: Loosen the lock nut 2 and turn the adjustment screw 1 cut as far as possible without using force, Loosen the lock nut 4 and tum the adjustment screw 3 back until a 0.60 mm feeler gauge can be inserted between piston 5 and the valve. ‘Tum in the adjustment sorew 3 unt it clamps on the feeler gauge . The piston 5 is pushed back. Set the vaive play of 0.50 mm on adjustment screw 3, tighten the lock nut 4. Push the feeler gauge 0.30 mm between piston Sand the valve. Push the rocker lever with the screw driver in the area of piston onto the valve, unti piston 5 stops. Hold piston § down and turn in the adjustment screw until the valve clearance is set Tighten lock nut 2. After adjustment, check the clearance by turing the plunger rod 7, it must have some play.Adjustment screw Lock nut Adjustment screw Lock nut Piston Relief bore 4 2 3 4 5 6 7 Rod ‘Benennung / Deserption / Denomination D S24 TITLE Model i noes D926 TITLE Datum / Etition / Valve adjustment “ZBS" Date 12/2003Cylinder head gaskets On D 904 / 906 / 914 / 916 / 926 TI engines, soft cylinder head gaskets are installed, On D 924 / 926 T-E/ THE engines, the soft cyinder head gaskets have been replaced by metallic elastomer gaskets. Important: On engines, which were equipped with soft cylinder head gaskets, reinstall soft gaskets. If metallic elastomer gaskets were installed, also use the same metallic elastomer gaskets due to the different cylinder liner protrusion to the crankcase and the grooves on the seating surface of the gasket.Soft cylinder head gasket Typ 904/914/ 924 Mode! Medel 908/916 / 926 ‘Benennung / Description / Denomination Datum 7 Edition / Dee Cylinder head gaskets 12/2003 Page FeuilleCylinder head Individual cylinder heads are installed in transverse current principle. The inlet channel is designed as a twist channel ‘The connection to the crankcase is made via 6 sews. Valve guides 1 and valve seatrings 2 are inserted in the cylinder head and can therefore be replaced. Depending on the enginetype, one or two valve springs are installed on the outlet valve. ‘On D914, 916, 926 TI engines, valve shaft seal rings are installed on some engine types On 924 / 926 T-E/ TLE engines, the installation of valve shaft seal rings is standard Valve seat angle: D 904/906 NA D 904 / 906 TB, 904 T, 906 T/TI, 914 T/TI, 916 TTI D 926 TI, 928 T-E/TI-E, 926 T-E/ TLE Inlet valve = 45° Inlet valve 30° Outlet valve = 45° Outiet valve == 45° Valve sprint 904/908 914/ 916/926 TI Outer spring: Length rot tensioned, normal 7mm Length rot tensioned fatigue limit = 55mm Inner spring Length rot tensioned normal Length rot tensioned fatigue limit D 926/926 T-E/TIE Outer spring: Length rot tensioned normal = 635mm. Length not tensioned fatigue limit 61.5 mm. Inner spring Length rot tensioned normal 555mm Length rot tensioned fatigue limit, = 63.5 mm Allen head screws: Length normal = 161,3mm Length limit value = 162.5 mm ‘Tightening torque spectfication for soft cylinder head gaskets: Pretension Nm 30 2° 30 +30 + 60+ 60 = 180 ‘After installation, run the engine until warm, let it cool off and re-tighten when cold Re-tightening value : £° 9 Tightening torque spectication for metallic elastomer cylinder head gasket Pretension Nm 30 Nm 90 +" 70 +70 + 70 + 70 = 280 Sequence:4 2 3 4 5 6 7 8 9 1 Datem Edition! Dato 12/2003, Valve guides Valve seat rings Inlet valve Outlet valve Spring plate, bottom Spring plate, top Valve springs, outside Valve spring, inside Valve stem Valve shaft seal rings ‘Benennung ! Descripton / Denomination Cylinder head Tp. Mode! Type D904 914/924 D 906/916 / 926Cylinder liner ‘The cylinder fner 1 is a wet liner. Itis sealed to the crankcase on the collar side with an O-ring 2 ‘The O-ring 2 on the collar side drops out for engines D 914 / 916 / 924 / 926 beginning with serial number 2003 01 2970 ‘Three O-rings 3 are usedto seal the fluid chamber down to the crankcase. ‘The modification from 2 to 3 O-rings was for D 924 / 926-E engines beginning from ca 03 12001 Removal: Remove the cylinder head and the oil pan, remove the piston with the connecting rod. Pull the cylinder Iner with the pulling device. Note: In case the cylinder liner is being teused, mark the liner and the crankcase. Installation: Clean the liner flange, the bore znd seating surfaces for the O-rings Lightly grease Oxings with GBUY 131 and push the cylinder liner in the crankcase, Cylinder liner protrusion to crankcase: ‘The liner protrusion ,A* fo the crankcase with installation of soft cylinder gasket is +0.03 to 40.08 mm, For installation of metallic elastomer cylinder head gasket, the protrusion is + 0,05 b + 0,1 mm, Note: If the cylinder liner protrusion ,A* to the crankcase is not sufficient, then it Is possitle to re- machine the crankcase collar and use a repair cylinder liner with a higher collar to obtain the correct liner protrusion A’. ‘When re-machining, try to obtain the upper limit of the cylinder liner protrusion ,A*Z, KEKE (ELLIS i SCR SEE cles = _ Qe 8 SY zzz 77d wee i 2 O-ring (collar side) 3 O-ring (bottom) 1D 904/914/ 924 0 906/916 / 926 ‘Benennung / Description / Denomination10 Piston and connecting rod Piston: All engine models use the 3-ring piston 1 with cast ring carrier 2 for the upper seal ring ‘The difference between the pistons is a different combustion cavity 3, shape and diameter for individual engine models. Piston rings: Different diameters: D904 / 906 @ Piston 115 mm D 914/916 @ Piston 120 mm 1D 924 / 926 @ Piston 122 mm NA/TB - engines: Ring 4 ‘Dual trapezoid ring, chrome-plated and convex Ring 5 Minute ting, all sides iron oxidized Ring6 = _ Hose spring ring chrome-plated (oll scraper ring) Ring 4= Dual trapezoid ring covered with Molybdan, convex Ring 5+6 same as NA/ TB engines. T/TI- engines: Note: When installing the piston rings, the top mark must point o the piston bottom Piston pin: ‘The pin 7 (@.45 mm) is pressure lubricated via the bored connecting rod 8 Its floating in the piston and attached with retaining rings. Piston cooling nozzle: All engine models are equipped with piston cooling nozzies 9. ‘Opening pressure: 0.8 - 1 bar, Tightening torque = Nm 30, retaining fluid Loctite 262 o1 Omnifit 100M.Piston and connecting rod removal and installation: Removal: Remove the cylinder heat! and the oil pan. Loosen and remove the mounting bolts 10. Remove the bearing cap 11 with bearing shell Push the piston 1 with connecting rod 8 through the cylinder liner. Note: If the pistons or liners are reused, reinstall them as a pair. Do not mix up the connecting rod bearing shells. Installation: When installing the piston on the connecting rod &, position the recess for the piston cooling razzie 9 on piston 1 at the marked connecting rod side. ‘The marked connecting rod side must be positioned at the right side, as seen from the flywheel {engine in normal position) Position the piston rings on rods to each other and tighten with piston ring compressor, Insert the bearing into the connecting rod 8 and push the connecting rod 8 and piston 1 into the cylinder liner until the bering shell touches the pin. Install the bearing cap 11 with bearing shell, The marks to the connecting rod must match. Install the mounting screws 10 ard tighten according to tightening torque. Mounting bolts: Length normal = 65~0.6 mm Length limit vaue = 65.5 mm Tightening torque connecting rod: —Pretorque Nm 30° 45 + 30 + 30= 105 Typ 904/914 /924 Model 906/916 / 926 iat Page 10 Feuille. ‘Benennung//Deszription / Denomination ‘Datum /Eaition /Date 421 2003, Piston and connecting rodSSS SSS wl 3} \ p b 9 Piston cooling nozzle 10 Connecting rod bolts 11 Bearing cap RRS ESS SONNE Connetting rod description 4 Piston 2 Ring carrier 3 Combustion chamber 4 Double Acme ring 5 Minute ring 6 Oil scraper ring 7 Piston bolt 8 Connecting rod D904/ 914/924 D906 / 916/926 Mode! Type Typ ‘Benennung / Description / Denomination Blatt Page Feullle Piston and connecting rod Datum / Edition / 12/20031 Check piston clearance ‘The gap between the piston and the cylinder heads 1.15 to 1.67 mm. When changing piston, connecting rod, crankshaft or crankcase, the piston clearance (gap) can be measured. Check: Place a test bridge with two test dial gauges ciosswise of the engine onto the crankcase. Measure the highest pont of the piston to the crankcase. Determine the medium value (dimension A) of two measured values and compare it with the data given in the chart. Note: On the test dial gauge holder, note the various test points for the test dial gauges, in relation to the piston diameters. 904/906 =@Piston 115mm = @ Test point 106 mm D914/916 =@Pistor120mm = @ Test point 115 mm 10924/926 =@Pistor122mm = @ Test point 115 mm The values given in the chart are only valid for these test points Chart - control dimension - piston clearance Dimension A (mm) Medium value of two Cylinder head gasket Cylinder head gasket test points thickness“ 7.3mm Soft gasket -0,24 bis + 0,09, 1.25 mm Metalic ielastomer gasket‘Benennung / Description / Denomination ‘Datum / Edition / Hie Check piston clearance 12/200312 Crankshaft and bearing ‘On 4 cylinder engines, the crankshaft 1 is placed in five bearings, on 6 cylinder engines in seven, ‘Two counterweights 3 are welded onto each connecting rod bearing 2. ‘A mated bearing 4 with four thrust washers 5 is installed in the bearing base. ‘The fixation goints in the thrust washers 5 or in the recesses in the bearing base are designed in such a way, that the thnust washers § cannot be installed the wrong way. ‘The lubrication pockets inthe thrust washers 5 face the crankshaft walls when installed ‘The main bearing pins 6 have a diameter of 98 mm, the connecting rod pins 2 have a diameter of 75 mm. To prevent rotation vbrations, 2 vibration damper is installed on the fen side. D 904 NA/ TB engines do not require a vibration damper. Bearing base - Numbering system: From the flywheel side on, the main bearing capsare numbered with running numbers 1, 2. 3, etc. In the crankcase, sarting from the flywheel side, the bearing cap are numbered in sequence, ‘The crankcase numbers are engraved in the crankcase on the underside of the crankcase, opposite the fanside bearng base into the crankcase. ‘All main bearing caps are numbered with the crankcase number. ‘The numbers are on the left side, as seen from the flywheel side onto the engine. Crankcase position: Oil pan side points upward. Note: ‘Main bearing cap numbers and crankcase numbers must match for installation, Tightening torque - main bearing: Pretorque Nm 30 X” 30 +30 + 30 = 90Oar on a tum /Ealtion/ Date 12/2003 Crankshaft Bearing pins Counterweight Bearing Thrust washer Main bearing pin We ‘Mode! Type ‘Benennung/ Description / Denomination D 904/914 / 924 Crankshaft and bearing 2 Page FeuilleCrankshaft Bearing pins Counterweight Bearing Thrust washer 1 2 3 4 5 6 Main bearing pin ‘Benonnung { Description / Denomination ‘en Model D906 916 / 926 Crankshaft and bearing 42 | 2003 42413 Camshaft and valve drive ‘The camshaft 1 is made of tempered stee!. ‘Cam and running surfaces of the bearing pins are hardened. ‘The valves are actuated via plungers 2. ‘Steel plungers 3 and rocker arms 4. “The parts are the same for inlet and outlet valves. To improve the gliding abifty betweem ca, and valve plunger, was on D 924 / 926-E engines beginning from ca. 03/2001 a cam lubrication introduced. “The region of cam and valve plunger is lubricated by spray nozzles mounted in the crankcase in the area of the vaive plunger bores, Camshaft - set in crankcase: Acylinderengne = S times 6cylinderengne = 7 times. Cam stroke inlet 5mm Cam stroke outlet mm Control times: Inlet opers. 18 KWv. OT Outlet closes 45° KW. UT. Outlet opens 54° KWvv. UT. Outlet closes 14” KWn. OT KW = Kurbelwinkel = Crank angle, OT = Oberer Totpunkt = upper TC, UT = Unterer Totpunitt = lower TC. Tightening torque for screws 6: 10x 65 M10 x 110 (zBs) Nm 65 Nm 754 Camshaft 2 Tappet 3. Steel push rods 4 Rocker lever 5 Screws 1D 904/ 914/924 D 906/916 / 926 13 pe Tye Mode! YI14 Lube oil circuit ‘Schematic view on D 904, 914, 924 engines. CON anne on a RBoerpas NBRBREBRBVBBSSWSS Oil pan Suction funnel Lube oil pressure pump Relief valve (opening pressure 9¢ 1 bar) Oil cooler Oil filter Bypass valve (opening pressure 6 1 bar) Main bearing - crankshaft Connecting rod bearing Piston pin Piston cooling nozzle (opening pressure 0.8 - 1 bar) Connection for injection pump Connection for hydraulic pumps - auxiliary drive Intermediate gear Drive for injection pump Fan drive Lubrication nozzle for gears Connection for air compressor Connection for cooling pump Bearing - camshaft Valve plungers Push rod Rocker lever Connection for turbo charger Oil pressure transmitter End regulating valve Cam lubrication‘Schwungradsite cote volant meteur Xx ‘lywhee! side D 90479141 924 Model D906 / 916/926 Benennung/ Deserption / Denomination ‘Datum Edition Lubrication circuit Date 12/200315 Oil pans Lube oil in oll pan: D904/914/924 max = 161 min = 401 S depending on version max = 20,51 ‘i min = 13,51 ot pate D906 /916/926 max =201 min = 10 I sependira ible incline postion to all sides: il pans with oil sump D 904/914 /924 = 45° (100%) D 906/916 /926 = 45° (100%) il pans without cil sump D904/914/924 = 3° (7%) 906/916 /926 = 3° (7%)4 cylinder oil pan 6 cylinder oil pan 9041914 / 924 9061916 / 926 ‘Benenmung / Description / Dentomination16 Lube oil pumps 904/914 RPM Supply gear width 0924 RPM. Supply gear width 0 906 / 916/926 TL RPM Supply gear width 0926 TLE RPM ‘Supply gear width Supply power: Pressure pump Supply gear width 18 mm= '591/ min/ 2100 ‘/min 74 1/ min | 2520 "min 79 1/ min / 2800 ‘min 831/ min / 2840 'imin ‘Supply gear width 27, mm= 89 1/ min / 2100 '/min 106 1/ min / 2620 ‘min 4481/ min / 2800 ‘min 1241/ min / 2940 "/min Pressure pump Engine n ‘/min '800 / 2000/ 2100 Pressure pump n'/min 2520 / 2800/ 2940 16/48 mm. Pressure pump Engine n ‘min Pressure pump n '/min 18/20mm 1500 / 4800 / 2000/2100 100 / 2520 / 2800 / 2940 Pressure pump + suction Engine n '/min Pressure pump n,'fmin Suction pump n ‘min Pressure pump Suction pump Pressure pump + suction puma Engine n "min '500 / 1800 / 2000 / 2100 Pressure pump n'/min = 2100/ 2520/ 2800 / 2940 Sucticn pump n '/min = 2100 / 2520 / 2800 / 2940 Pressure pump 7 130mm ‘Suction pump 30/33 mm ‘Supply gear width 15 mm= 591 / min / 2520 "imin 661 / min / 2800 ‘/min 691/ min 2940 "/min ‘Supply gear width 20 mm = Supply gear width 23 mm = €51/ min [2100 ‘min 91.1 min 12520 ‘min 7B1/ min / 2520 min 101 1/ min / 2800 min 87 1/ min / 2800 'fmin 106 1/ min / 2940 ‘min 911/ min / 2980 “min Supply gear width 30, mm = $8 17 min / 2100 ‘/min 4148 1/ min / 2820 ‘min 491 1/ min / 2609 ‘/min 46 1/ min / 2940 "min ‘Supply power / suction pump: Supply gear width 27 mm= 106 17 min / 2520 '/min 118 1/ min/ 2800 ‘min 424 17 min / 2940 "min Note: ‘Supply gear width 30mm = Supply gear width 33mm = 9B1/ min/ 2100 Ymin 108 1/ min / 2100 "/min 4481/ min / 2520 ‘imin 130 1/ min /2520 "/min 431.1 min / 2800 min 144 1/ min / 2800 ‘/min 138 1/ min (2340 "min 1811/ min / 2940 ‘min No suction pump is installed on 6 cylinder engines with oil pans without oil sump (Incline 3°)Axial play of feed gears normal 0.05-0.12 mm limit value 0.22 mm Backlash of oil pump gears 8,9 to drive gear 4on crankshaft: 0.15 — 0.25 mm Engine position: oil pan side points upward. Relief valve 2 relief pressure: 9+ 1 bar. Lube pressure pump removal: Remove the oll pan and the timing case. Remove the oil suction line from the pressure pump 4, Remove screws 3 and remove the pressure pump 4 from the crankcase. Hf suction pump 5 is instaled, the lube oil line 6 must also be removed. ‘Suction pump removal: Remove the oil pan and timing case. Remove the suction line from the suction pump 5. Remove the lube oil line 6. Remove screws 7 and remove the suction pump § ‘rom the crankcase. Lube oil pressure pump installation: Install the pressure pump on the crankcase. Tighten screws 3 lightly. Set the backlash between gear 8 and geat 1 on the crankshaft by moving the pressure pump 4, using @ feeler ‘gauge. Tighten screws 3, Install the suction line with seal. install the timing case and the oil pan I suction pump 5 is instaled, the lube oil line 6 must also be installed. Suction pump installation: Install the suction pump 5 on the crankcase. Tighten screws 7 lightly. Set the backiash between the gear 9 and gear 7 on the crankcase by moving the suction pump 5, using a feeler gauge. Tighten screws 7. Install the suction lines with seals. Install lube oil line 8. Install timing case and oil pan. Typ 904/914/ 924 Model D 906/916 / 926 Type ‘Benennung / Descrption / Denomination Lube olf pump17 Lube oil filter and oil cooler ‘The oll cooler is installed on the oil cooler housing, on the right hand side of the crankcase, when viewed onto the flywheel right. ‘The lube olf fiter can be installed ,hanging’ or , upright’ on the cil cooler housing or away from the oil cooler housing, depending on the engine model. ‘When its installed away fom the oil cooler housing, the connections must be connected as shown on page 17.1 Removal: Drain the coolant on plug5. Remove the lube oil fiter 4 from the oil fiter console 3. Ifthe lube oi fier is installed away fiom the oil cooler housing, remove the oil ines from the oil cooler housing 2. Remove the connector screws from the oil cooler housing 2 to the crankcase. Remove the oil cooler housing 2 together with the ol fiter console 3 and the oil cooler 1 from the crankcase. Note: ‘To remove the oil cooler tousing 2, only the two outer screws on the oil filter console 3need to be removed (see arrows). Important: When removing the oil cooler housing 2, make sure that the bypass valve between the oll cooler housing 2 and the crankcase is also removed. Installation: Inset the piston of the bypass valve into the centerbore in the crankcase. Install the oll cooler housing 2 with oil cooler 1 and new seal onto the cankcase. Install the lube oil iter 4 onto the Gil fiter console 3 or the ol lines onto the oil iter housing 2. Install the coolant drain plug 5 and add coolant. Check the engine oil level add oil as necessary. Note: Depending on the size of fhe oil cooler, there might be an intermediate plate installed between the olf cooler housing andthe crankcase.Lube oil filter installed "hanging" from the oil cooler housing Oil cooler Oil cooler housing Oil filter console Oil filter Coolant drain plug aaens Benennung / Deseription / Denomination Typ 904/914 / 924 Mods! 906/916 /926 Type Datum Eton Lube oil filter and oil cooler Blatt Ps 12/2003 a a FoulleLube oil filter installed "upright" on the oil cooler housing 4 Oil cooler 2 Oil cooler housing 3 Oil filter console 4 Oil filter 5 Coolant drain plug 2 Oil cooler housing 5 Coolant drain plug Connection from filter Connection to filter Benennung / Description / Denomination Tye 904/914 924 Mods! 906/916 / 926 Ye Datum / Edition / Lube oil filter and oll cooler Dato 12/2003 Batt Page Feuille 7418 Coolant circuit ‘Schematic view on D 906, 916, 926 engines. Coolant pump Line to heater Coolant drain Oil cooler housing Cylinder liner bushing, cylinder heads Connection for bleeder line Thermostat housing, thermostats Return line from heater war aanon oa Water cooler 10 Water filter Opening begin of thermostats = 71°C, 79°C, 83°C.Os dad Db WN YY 908/914 /:924 ‘Benennung / Description / Denomination 906/916 / 926 ‘Datum / Enttion/ Date 421 2003 Coolant circuit19 Water filter ‘To improve the quality of ine coolant, water filters are installed on the newer engines ot on E- engine. Due to this measure, the coolant is filtered in the euxiliary flow and is cleared of dirt or ust particles. In addition, due to a cherrical additive in the water filter (DCA 4) , the coolant system or any parts which come in contact with the coolant, such as coolant pump, cylinder liners etc. are protected from cavitation, corrosion, scale deposits and foam formation, ‘Water filters can be instaled externally or on the thermostat housing, For water fitter change intervals, see Maintenance and Inspections. For coolant mixture, see Service Fluids, To change the water filter: External installation: Close the shut off vaives 1,2. Remove the water fter element 3. Clean the sealing surface on the filter console, Install new water filter element 3, lightly lubricate the rubber seal ring with cil, and tighten by hand. Open the shut off valves 1, 2. Check the coolant level, add more coolant as necessary. Installation on thermostat housing: Close the shut off valve 1 on the thermostat housing, bring it from horizontal to vertical position to the water fiter. Remove the water fiter element 3. Clean the sealing surface on the filter console. Install new weter filter element 3, lightly lubricate the rubber seal ring with oll, and tighten by hand. Open the shut off valve 1, bringing it from vertical to horizontal position to the water filter. Check the coolant level, add more coclant as necessary.Water filter installation, external 1 Shut off valve 2 Shut off valve 3 Water filter 1 Shut off valve 3. Water filter Benennung / Description / Denomination Datum / Edition / Date 12/2003 Ye. Mode! ‘Type ‘Bratt Page Feullle 904/914 1924 D 906/916 / 92620 Coolant pump Coolant pump installed on the timing case In this version, the fan is hstalled on the coolant pump. ‘The coolant pump and the fan is driven by a gear. RPM: Engine nmin 1000 / 2400 Coolant pump nmin = = 2312/2428 ‘Supply power: approx... 270 I /min / 2312 '/min, approx. 284 | /min 2428 ‘imin Note The coolant pump must be replaced or overhauled if increased coolant or oil discharge is found on the leakage bores (see arrows). Oil canonly emerge on the leakage bore onthe neck of the housing, in frant of the timing case. Removal: Drain the coolant, remove the cooler and heater hoses. Remove the cooler, remove the fan 7. Remove the cable on the coolant temperature sensor. Remove the screws 1 onthe coolant pump. Only screws 1 with hex head must be rerroved. Push the coolant pump complete with thermostat housing cover 2 from the timing case or from the coolant collector fine Installation: Attach new O-rings 4 to the connector 3. Lightly ol the O-rings and push the connector 3 into. the coolant collector line Place a new O-ring with grease into the groove onthe coolant supply intake bore of the coolant pump to the timing case. Install new O-ring 6, lubricate it lightly. Push the coolant pump complete with thermostat housing cover 2 by turning the drive shaft - Until gear 6 has engaged - into the timing case or nto the connector 3 on the coolant callector line. Tum in screws 4 and tighten. Attach the cable on the sensor, install the fan 7, install the cooler and the cooler and heater hoses. Add coolant Important: 1 Before operating the coolant pump, make sure that coolant has been added, |Mounting screws Thermostat housing Connector O-rings O-ring Gear Fan Fan hub Shaft seal ring 40 Lifetime seal 11 Idler 42 Thermostats WCOVAMREN= Typ (0. 904/914 / 924 ‘Benennung / Descrition / Mosel 90% Mocel 906/916 / 926 Denomination Coolant pump Bat ‘Datum / Edition’ 0 ate 42/2003 20 Feuille20.1 Coolant pump Coolant pump integrated in the timing case to engine No. 93 01 1641 ‘The coolant pump is driven by a gear. RPM: Engine n'imin — =1800 / 2000/2100 Coolant pump — nmin. =3027 13363 / 3532 ‘Supply power: approx. 270 | /min / 3027 ‘/min, approx. 300 | /min / 3363 “/min approx. 315 | min 13532 '/min Note: The coolant pump must be replaced or overhauled if increased coolant or oil discharge is found on the leakage bores in the timing case (see arrows). Removal: Drain the coolant, remove cover 1. Remove screw 2. Remove cover 3 and spacer 4. Pull the coolant pump with the pulling device from the timing case. Installation: ‘Attach new O-rings 5. Lubricate the coolant pump on the O-rings 5 and on the surface between the O-rings 6 or the intake bore in the tining case with grease (Staburags NBU 12) Push the coolant pump into the timing case in such a way that the thread for the screw 2 in the coolant pump and the bore in the timing case maich when the coolant pump is pushed in. Apply a locking fluid (Loctite 243) to the threads of screw 2 and install with spacer 4 and cover plate 3 and tighten according to torque specifications. Measure the gap between the impeller 3 and the timing case with a feeler gauge. Install cover 1 with new O-ring 7 and add coolant. Tightening torque for screw 2 = Nm 15 Gap between impeller and timing case = 0.9 -1,113 mm Note: The given dimension is the complete dimension on both sides of the impeller. When checking the dimension with the feeler gauge, use half the value. Check the axial play: ‘The axial play of the coolant pump must be checked for the first time at 6000 hrs. andthen every 3000 hours thereatter. Drain the coolant, remove the cover 4 install commercially available test gauge holder with test gauge to the shaft of the coolant pump (see afrow) and move the impeller 6 with the screw in one of the two threads in the impeller 6 axially back ard forth, Read the axial play. Permissible axial play = 0.1 mm Limit value = 042mm If the given limit value is exceeded, the coolant pump must be replaced. important | Before operating coolantpump, make sure that coolant has been added1 2 3 4 5 6 7 8 9 1 10 Cover Mounting screw Cover Spacer O-rings Idler O-ring Gear Shaft seal ring 0 Lifetime seal Datum Edition /Date 42/2003 ‘Benennung / Description / Denomination Coolant pump Typ D904 914/924 Model 906/916 /92620.2 Coolant pump Coolant pump integrated in timing ca Repair solution to EngineNo. 93 01 1641 ‘The coolant pump is driven by a gear. Important: When changing the coolant pump integrated in the timing case until above engine No. (see 20.1), only the repair solution may be used. If the coolant pump is still mounted the old way (see 20.1) then a M 10 x1/ 20 mm deep thread must be made into the mounting bare in the timing case (see illustration). RPM: Engine n '/min 1800 / 2000 / 2400 Coolant pump —_n ‘/min 3027 13363 / 3532 ‘Supply power, approx. 270 I min / 3027 '/min, approx. 300 i /min / 3363 ‘min ‘approx. 315 | min / 3532 ‘min Note: ‘The coolant pump must be replaced or overhauled if increased coolant or oil discharge is found on the leakage bores in the timing case (see arrows), Removal: Drain the coolant, remove cover 1. Counter screw 2 and loosen the locknut 3. Remove sorew 2 along with cover 4 and spacer 5, Pull the coolent pump with the pulling device from the timing case. Installation: Install new O-rings 6, Lubricate the coolant pump on the O-rings 6 and on the surface between the O-rings 6 or the intake bore in the timing case with grease (Staburags NBU 12). Push the coolant pump into the tiring case in such a way that the bore in the coolant pump andthe bore or the thread for the mounting screw match when the coolant pump is pushed in. ‘Apply a locking fluid (Loctite 243) to the threads of screw 2. and install with spacer § and cover plate 4 and tighten according to torque specifications. Bring the cover plate 4 into the correct position to the leakage bore. Counter the screw 2 and tighten the locknut 3. Measure the gap between the impeller 4 and the timing case with a feeler gauge. Insiall cover + with new O-ring 8 and add coolant. Tightening torque for strew 2= Nm 15 Gap between impeller and timing case = 0.9-1,113 mm Note: The given dimension is the complete dimension on both sides of the impeller. When checking the dimension with the feeler gauge, use haf the value.‘Check the axial play: The axial play ofthe coolant pump must be checked the first ime at 6000 hours and then every 3000 hours thereafter. Drain the coolant, remove cover 1. Install a commercially available dial gauge holder with dial gauge on the shaft of the coolant pump (see arrow) and move the idler 7 back and forth with a screw which was inserted in one of the two threads in the idler 7. Read the axial play. Permissible axial play = 0.1 mm Limr vaiue = 012mm Ifthe given limit value is exceeded, then the coolant pump must be replaced, [ important: 1 | Before operating cootant pump, make sure that coolant has been added. D904 /914/924 Typ Model 1p 906 / 916 / 926 ype Benennung / Description / Denomination Datum / Edition! Coolant pump Date 12/200341 Cover 42 Mounting screw 13 Lock nut 14 Cover plate 415 Spacers 416 O-rings 17 Idler 48 O-ring 419 Gear 20 Shaft seal ring 24 Lifetime seal 1D 904/ 914/924 Benennung / Deserition / Model 1p 906/916 / 926 Denomination ‘Datum / Edition / Coolant pump Page 20.2 12/2003 Feulle20.3 Coolant pump Coolant pump integrated in timing case from engine No. 93 01 1642 The coolant pump is driven by a gear. RPM: Engine 1n ‘min 100 /1800 / 2000 / 2100 Coolant pump ——_n ‘Imin 2523 / 3027 / 3363 / 3832 Supply power approx. 225 min /2523 "min, approx. 270 | min / 3027 ‘min approx. 300 | /min / 3363 ‘imin, approx. 315 | /min / 3532 '/min Note: ‘The coolant pump must be replaced or overhauled if increased coolant or oll discharge is found on the leakage bores in the timing case (see arrows). Removal: Drain the coctant, remove cover 1. Remove screw 2 and pull the coolant pump with the pulling device from the timing case. Remove screw 3, remove cover plate 4 and spacer §. Clean the threaded bore and the leakage bore. Installation: Install spacer 5, cover plate 4 and screw 3. Install new O-rings 6. Lubricate the coolant pump cn the O-rings 6 and on the surface between the O-rings 6 or the intake bore in the timing case with grease (Staburags NBU 12). Push the coolant pump into the timing case in such a way that the recess in the coolant pump housing and the positioning screw in the timing case match when the coolant pump is pushed in. ‘Apply a locking fluid (Loctite 243) to the threads of screw 2, install tighten according fo torque specifications. Measure the gap between the impeller 7 and the iming case with a feeler gauge. Install cover 1!with new O-ring 8 and add coolant. Tightening torque for serew 2= Nm 15 Gap between impeller and timing case = 0.9-1,113 mm Note ‘The given dimension is the complete dimension cn both sides of the impeller. When checking the dimension with the feeler gauge, use half the value.Check the axial play: ‘The axial play of the coolant pump must be checked the first time at 6000 hours and then every 3000 hours thereafter. Drain the cootant, remove cover 1 Install a commercially available dial gauge holder with dial gauge on the shaft of the coolant pump (see atrow) and mave the idler 7 back and forth with a screw which was inserted in one cf the two threads in the idier 7. Read the axial play. Permissible axial pay = 0.1mm Limit value = 012mm Ifthe given limit value is exceeded, then the coolant pump must be replaced Important: Before operating coolant pump, make sure that coolant has been added. Benennung / Description / Typ 0. 904/ 914/93 Denomination Mode! no Mocel 906/916 / 926 xem Eaton! Coolant pump 42/2003Zin (Ad Wl: Y Cover Mounting screw Screw Cover plate Spacer O-ring Idler O-ring Gear 10 Shaft seal ring 114 Lifetime seal CONanaons Tye 0 904/914/ 924 Bonennang /Deserpton’ won Mowe! p 906/916 /926 Denomination Datum / Edition Date 1212003 Coolant pump20.4 Coolant pump Coolant pump integrated in timing case With collar bearing (bushings: Up to engine nr. 2001 02 1093 The coolant pump is driven by a gear. RPM: Engine 1n '/min 1500 1800 / 2000 / 2100 Coolant pump ——_n “/min 2523 / 3027 / 3363 / 3532 ‘Supply power: ‘approx. 225 | min / 2523 ‘min, approx. 270 | /min 3027 ‘/min approx. 300 I /min / 3363 "min, approx. 316 | /min / 3532 ‘/min ‘The coolant pump must be replaced or overhauled if increased coolant or oil discharge is found on the leakage bores in the timing case (see arrows). Removal: Drain the coctant, remove cover 1. Remove the hollow screw 2 and remove the cover 3 Remove the lube oil line 4 on the crankcase. Loosen the mounting screw 5 (lube oll nazzle) and remove. Pull the coolant pump withthe pulling device from the timing case. Clean the threaded bore and the leakage bore. Installation: Install new O-rings 6. Lutricate the coolant pump on the O-rings 6 and on the surface between the O-rings 6 or the intake bore in the timing case with grease (Staburags NBU 12). Fush the ‘coolant pump into the timing case in such a way that the recess in the coolant pump housing and the positioning screwin the timing case match when the coolant pump is pushed in. Apply a locking fluld (Loctite 243) to the threads of mounting screw 5 (lube oil nozzle), instal and tighten according to torque specifications. install the cover plate 3 and hollow screw 2 with new O-ring and tighten everything, Measure the gap betweea the impeller 7 and the fing case with a feeler gauge. Instill cover ‘with new O-ring 8 and add coolant. Tightening torque for screw 5 = Nm 20 Gap between impeller and timing case = 0.9 - 1,113 mm Note: The given dimension is the complete dimension cn both sides of the impeller. When checking the dimension with the feeler gauge, use half the value. _iaportant Before operating coolant pump, make sure that coolant has been added.10 Cover Hollow screw Cover plate Lube oil line Mounting screw (lube oil noozle) O- rings Idler O-ring Gear 10 Shaft seal ring 11 Lifetime seal anens earn Typ 0 904/914 / 924 ‘Benennung / Description / Be Hose! 0 906/916 / 926 Denomination ‘Datum / Edition Date 42/2003 Coolant pump Feuille20.5 Coolant pump Coolant pump integrated in timing case With collar bearing ( bushings) From engine No. 2001 02 1094 ‘The cootant pump is driven by a gear. RPM: Engine p'/min 1500/ 1800 / 2000 / 2100 Coclant pump n'/min 2523 /3027 / 3363 / 3532 ‘Supply power: approx. 225 1/ min / 2523 'Imin, approx. 270 | / min / 3027, ‘min ‘approx. 3001/ min / 3363 '/min, approx, 316 1/ min / 3532 "/min Note: ‘The coolant pump must be replaced or overhauled if increased coolant or oil discharge is found on the leakage bores in the timing case (see arrows). Removal: Drain coolant, remove cover 1. Remove the hollow screw 2 and remove the lube oil ine 3 on the crankcase . Loosen the mounting screw 4 ( lube oil nozzle } and remove with cover plate 5. ull the coolant pump wih the pulling device from the timing case. Clean the threaded bore and the leakage bors. Installation: Install new O-rings 6. Lubricate the coolant pump on the O-rings 6 and on the surface between the O-rings 6 or the intake bore in the timing case with grease (Staburags NBU 12). Push the coolant pump into the timing case in such a way that the recess in the coolant pump housing and the positionng screw in the timing case match when the coolant pump is pushed in, ‘Apply a new O-ring 7 to the mounting screw 4 (lube oil nazzie) and apply a retertion fluid (Loctite 243 } to the threads, install cover plate 5 and tighten according to torque specications. Measure the distance *A’ between the installation surface cover 1 and the outer impeter 8 with a depth gauge. Note: The coolant pump is installed correcty if the noted gab is retained. Install the tube oil line 3 with new seal rings to the mounting screw 4 (lube oil nozzie) and install on the crankcase. Measure the gab between the impeller 8 and the bore in the timing case with a feeler gauge. Install cover 1 with new O-ring 9 and add coolant. = Tightening torque for mounting screw 4 =Nm 20 Distance “A” between the installation surface cover 1 and the outer impeller 8 2+ 1,3/- 1 mm Gap between the impeller 8 and the bore in the timing case =0,9-1,143 mm Note: The given dimension is the compiete dimension an both sides of the impeller. When checking the dimension with the feeler gauge, use half the value Caution: Make sure that coolant has been added before operating the coolant pump.“yy 6 ens 9 i 8 1 12 WwW 7. 10 be 7 1. Cover 2. Hollow screw 3. Lube oil line 4, Mounting screw (lube oil Nozzle) 5. Cover plate 6. O-rings 7. O-ring 8. Idler 9, O-ring 10, Shaft seal ring 11 Slipring Seal 12 Gear Typ D904 /914/924 Model D906 /916/926 Benennung / Destription/ ‘Datum / Edition Coolant pump Date Page 12/2003 Foulle21 Fan drive ‘The fan can be driven on the engine with a gear drive, gear drive and fan coupling or Visco coupling Drive with gear Bearing with ball bearing, to engine No. 89 01 2496 Removal and disassembly: Loosen nuts 1 and remove. Remove the fan drive from the timing case. Remove screws 2 and remove with washer 3, Pull gear 4 with commerdally available puller from shaft 5. Release the snap rings 6 and 7. Knock shaft § with ball bearing 8 from housing 9. Drive the ball bearing 10 or the two row ball bearing 11 from housing 9 with a mandrel. Drive out shaft seal ring 12 with a mandrel ‘Assembly and installation: Press new shaft seal ring 12 into housing 9. Lubricate the sealing lip lightly with oil. Push the ball bearing 10 or the tworow ball bearing 11 intohousing 9. Insert the snap ring 7. Apply retaining fluid ( Omnivisc 1002 or Lociite-Silicon transparent) to the seat for the ball bearing 8 in housing 9. On shaft 6, apply retaining fiuid (Loctite 638( to the seat for ball bearing 10, 11 and push the shaft 5 with ball bearing 8 into housing 8. Insert snap ring 6. Push the gear 4 onto shaft 5. insert the screw 2 with washer 3 andtighten according to torque specfication. Install new O-ring 13 and lubricate it lightly with oll Push the fan drive into the timing case. Note the tooth mesh! Install nut 1 and tighten, Tightening torque for screw 2: Pretorque Nm30 =” 50 Nm 120aT es Ae 2 3 +) 41 + 8 3 5 12 10 6 7 1 7 RI aS 4 2 is 3 Pater 5 2H 13 6 7 Nuts 7 Snap ting 8 Screw 8 Ball bearing 9 Washer 9 Housing 40 Gear 10 Ball bearing 14 Shaft 11 Ball bearing 12 Snap ring 12 Shaft seal ring 13 O-ring Typ. D904 /914/ 924 Model D906 / 916 / 926 ‘Benennung ! Description / Denomination Datum / Edition / Fan drive Di 42/200321.1 Fan drive Drive with gear Bearing with ball bearing, from engine No. 89 01 2497 Removal and disassembly: Loosen nuts 1 and remove, Remove the fan drive from the timing case. Remove screws 2 and remove with washer 3. Remove gear 4 from shat §, Release the snap ring 6. Knock shaft 5 with ball bearing 7 from housing 8. Drive the ball bearing 9 or the two row ball bearing 10 from housing 8 with a mandrel. Drive out shaft seal ring 11 with a mandrel, Assembly and installation: Press new shaft seal ring 11 into housing 8. Lubricate the seeling lip lightly with oi, Push the tall bearing or the two row ball bearing 10 into housing 8. Insert the snao ring 6. Apply retaining fluid ( Omnivisc 1002 or Loctite-Silicon transparent) to the seat for the ball bearing 7 in housing 8. Push shaft § with ball bearing 7 into housing 8. Push the gear 4 onto shaft 5. Insert the screw 2 with washer 3 and tighten according to torque specification. Install new O-ring 12 and|ubricate it ightly with oil Push the fan drive into the timing case Note the tootn mesh! Install nut 1 and tighten. Tightening torque for screw 2:Pretorque — Nm30_ 1°50 Nm 120Oaaen= ‘Datum / Editon / Date 1212003 Nuts Screw Washer Gear Shaft Snap ring ‘Benennung/ Description / Denomination 7 Ball bearing 8 Housing 9 Ball bearing 40 Ball bearing 44 Shaft seal ring 42 O- ring Fan drive Tye Model D906 / 916 / 926 Type Blatt Page Feuille 4 © 2 3 a 1 a Liz |—_ 5 19 6 1 S 2 _ NOt: —4 = 2 N 3 Ute 5 1 10 6 904/914 / 924 2A21.2 Fan drive Fan coupling 2 -stage and 3-stage, drive with gear and bearing with ball bearing. Removal and installation of fan from fan coupling (3-stage): Remove nuts 1, push coaling fin ring 2 off. Remove screws on magnetic ring 3 and remove the magnetic ring 3. Remove nuts 4 and remave the fan. Install in reverse order. IF the fan drive speed camat be reached, for example due to a power supply problem, etc., the fan coupling can be mechanically blocked. Inserttwo screws 5 (M 6 x 10) tightly through the ‘angle in the threads in the cooling fin ring. Removal and disassembly: Remove the cable 6 fromthe distributor point. Loosen nuts 7 and remove, Remove fan drive from timing case. Remove screw 8, remove waster 9 and remove the fan hub 10 with fan coupling 11 from the beating housing 12 ot from the fan shaft 13. Remove screw 14 end remove with washer 15. Remove gear 16. Drivefan shaft 13 with ball bearing 17, 18 rom bearing housing 12, Release snap ring 19 and hitball bearing 20 from bearing housing 12 with ‘a mandrel. Aiso drive outthe shaft seal ring 21 wif a mandrel Note: To disassemble and assemble the fan drive, we recommend to loosen and tighten screw 8 on the fan drive installed on the engine, while holding the ring gear on the flywheel ‘Assembly and installation: Press in new shaft seal ring 21 into the bearing hausing 12. Grease the sealing and protective lip lightly. Push in the bal bearing 20 and engage the snap ring 19. Guide the fan shaft 13 int the bearing housing 12 and push through the shaft seal ring 21 and ball bearing 20 to the stop. Set the gear 16 onto the fan shaft 13. Insert screw 14 with washer 15 and tighten accarding to torque specification. Press the ball bearing 17, 18 over the fan shaft 12 into the bearing housing 12 Set the fan coupling 11 with fan hub onto the fan shaft 13, noting the pin 22. Attach the washer 9. Tum in the screw 8 and tighten according to torque specification. ‘Attach new O-ring 23 and lubricate itightly with ol. Push the fan drive into the timing case, noting the gear mesh. Attach nuts 7 and tighten. Connect the cable 6 to the distributor point. Tightening torque for screw 14: Pretoque Nm30 50 Nm 120 Tightening torque for strew 8 (2-stage): Pretorque © Nm30_—- Nm270 Nm 180 Tightening torque for screw 8 (3-stage|OaAkona Datum / Edition 7 Nuts Coolant fin ring Magnetic ring Nuts Screws Cable Date 12/2003 Fan coupling, 2 -stage o 2 $s un 7% a | | es ae SNH Fan coupling, 3-stage 3 5 14 22 7 Nuts 8 Screw 9 Washer 10 Fan hub 14 Fan coupling 42 Bearing housing Benennung | Description / Denomination Fan drive 1312 7 i | ie 48 Fan shaft 49 Screw 20 Washer 21 Gear 22 Ball bearing 23 Ball bearing 19 16 13 Snap ring 14 Ball bearing 15 Shaft seal ring 16 Pin 17 O-ring Typ 904/914 / 924 Type, 906/916 / 82621.3 Fan drive Fan coupling 2-stage and 3-stage, drive with gear and bearing with collar bearing For removal and installation of fan from fan coupling (3-stage}, see page 21.2. Not Ifthe fan drive speed camot be reached, for example due to a power supoly problem, etc., the fan coupling can be mechanically blocked. Inseit two screws 1 (M 6 x 10) tightly through the angle in the threads in the cooling fin ring. Removal and disassembly: Remove the cable 2 from the distributor point. Loosen nuts 3 and remove Remove fan drive from timing case. Remove screw 4, remove washer 5 and remove the fan hub 6 with fan coupling 7 from the bearing housing 8 or from the fan shaft 9 Pull the fan shaft 9 from the bearing housing 8 and lift out the shaft seal ring 10. Note To disassemble and assemble the fan drive, we recommend to loosen and tighten screw 4 on the fan drive installed on the engine, while holding the ring geer on the flywheel. ‘Assembly and installation: Press in new shaft seal ring 10 into the bearing housing 8. Lubricate the sealing and protective lip lightly with grease (Barierta L 55/3) Lubricate the fan shaft 9 and push it into the bearing housing 8. Set the fan coupling 7 wit fan hub 6 onto the fan shaft 9, noting the pin 11. Attach the washer §. Tum in the screw 4 and tighten according to torque specification. Place new O-rings 12, 13with grease into the grooves of bearing housing 8 and place into the timing case. Push the fan drive into the timing case, noting the gear mesh. Attach nuts 3 and tighten. Connect the cable 2 to the distributor point. Tightening torque for strew 4 (2-stage): Pretoque — Nm30 —- Nm270 Tightening torque for screw 4 (3-stage) Nm 180Fan coupling, 2-stage Fan coupling, 3-stage .74 8 9 13 X \ | 4 10 3 41 Screws 43 Fan coupling “ 2 Cable 414 Bearing housing 3 Nuts 415 Fan shaft 4 Screw 16 Shaft seal ring 5 Washer 17 Pin 6 Fan hub 18 O-ring 19 O-Ring ‘Datum / Edition / Date 4212003 ‘Benennung / Description / Denomination Typ 09041 914/ 924 Model 906 / 916 / 926 pe21.4 Fan drive Visco coupling, drive with gear, bearing with ball bearing Removal and installation of Visco coupling: Removal: Loosen the screws 1 and remove. Remove the Visco coupling 2 with fan 4. Remove nuts 3. Remove the fan 4 from the Visco coupling 2. Install in reverse order. Important: Place the Visco coupling only vertically (installation position), in horizontal position, thete is the danger that off runs out. Removal and disassembly of fan drive: Loosen nuts 5 and remove. Remove the fan drive from the timing case. Remove screw 6. Remove fan hub 7 from bearing housing 8 and fan shaft 9. Remove screw 10 and remove it with washer 11, Remove gear 12. Drive the fan shaft 9 with ball bearing 13 from the bearing housing 8 with mandrel. Release the retaining ring 14, push the ball bearing 15 and the shaft seal ring 16 with a manctel from the bearing housing 8. Assembly and installation: Press a new shaft seal rg 16 into the bearing housing 8. Lightly grease the sealingand protective lip. Pushin the ball bearing 15 and insert the retaining ring 14. Set thespacer 17 onto the fan shaft 9 and insert the fan shaft 9 through the shaft seal ring 16 and ball bearing 15 into the beating housing 8. Set the gear 12 onto the fan shaff, turn in the screw 10 with washer 14 and tighten according to torque specification. Push the ball bearing 13 over the fan shaft 9 into the bearing housing 6. Set the fan hub 7 onto the fan shaft 9, pay attention to the pin 18, Insert the screw 6 ard tighten according to torque specification. Install new, lubricated O-ring 19 to the bearing housing 8. Push the fan drive into the timing case. Note the tooth mesh! Attach nuts and tighten. Tightening torque for screw 6 : Pretorque Nm 30 Nm 270 Tightening torque for screw 10 : Pretorque Nm 30 x 60 Nm 120Visco- Coupling 18 8 9 5 15 12 Screws Visco coupling Nuts Fan Nuts Screw Fan hub Bearing housing Fan shaft 0 Screw Beavonaons Denomination Datum /Edtion 7 Date 1212003 ‘Benennung/ Description / 13 16 1719 1411 10 14 Washer 12 Gear 13 Ball bearing 14 Snap ring 1 Ball bearing 46 Shaft seal ring 47 Spacer 18 Pin 19 O-ring Typ 904/914 / 924 Model D906 / 916 / 926 Fan drive Foullle21.5 Fan drive Drive with gear, bearing with bearing bushings Removal and disassembly: Loosen nuts 1 and remove. Remove the fan drive from the timing case. Remove screw 2 and remove the fan hub 3 from the bearing housing 4 or from the fan shaft 6. Remove the fan shaft 5 from the bearing housing 4 and take cut the shaft seal ring 6. Note To disassemble and assemble the fan drive, we recommend to loosen and tighten screw 2 on the fan drive installed on the engine, while holding the ring gear on the flywheel Assembly and installation: Press in new shaft seal ring 6 into the bearing housing 4. Lubricate the sealing and protective lip lightly with grease (Bamierta L 55/3) Lubricate the fan shaft 5 and push it into the bearing housing 4. Set the fan hub 3 onto the fan shaft 5, noting the pin 7. Tur in the screw 2 and tighten according to torque specication. Place new O-rings 8, 9 wth grease into the grooves of bearing housing 4 and place int the {iming case. Push the fan drive into the timing case, noting the gear mesh. Attach nuts 1 and tighten. Tightening torque for screw 2: Pretorque Nm 30 Nm 2701 Nuts 2 Screw 3 Fan hub 4 Bearing housing 5 Fan shaft 6 Shaft seal ring 7 Pin 8 O-ring 9 O-ring Typ 904/914 / 924 ‘enonnang/ Breeripton/ con Mode! 906/916 / 928 Denomination Datum / Edition Date 12/200322 Fuel system Indiine injection pump ‘The fuel pump 3 draws fuel from the tank 1 through the precleaner 2 and pumps it under pressure via the fuel prefiters 4 and the fuel fine fiter§ to the suction chamber of the injection pump 6. ‘The fuel is held there at a pressure of approx. 0.5to 2 bar via the overflow valve. ‘The uel is pressurized and flows from the injection pump 6 va the injection lines to the fuel injectors 7 From there itis atomizedand sprayed into the combustion chamber. Excess fuel fromthe injection pump 6 and from the fuel injectors 7 is returned to the fuel tank. 1 (On fuel systems with prefiter 4 with water separator between the fuel tank 1 and the fuel pump 4, the precteaner 2 and the prefiter 4 between fuel pump 3 and injection pump 6 are not installed. This design protects the fuel pump 3 from wear. Proceed as follows, in that order: 1 Loosen the bleeder screw on the fuel prefiter 4. 2 Loosen the bleeder screw on the fuel fine iter 5. 3 Loosen the fuel ine from the fuel fine filter 5 to the injection pump 6 on the injection pump. 4 Loosen the overfow valve 8. 5 Loosen the union nuts on the injection lines on the fuel injectors 7. From point 4 to 4, actuate the hand pump on the fuel pump 3 until fuel emerges without air bubbles. Retighten the strews. ‘At point 5, actuate the starter until fuel emerges without air bubbles. Retighten the lines. Not If there is a prefilter 4 between the fuel tank 1 and the fuel pump 3, the bleeder screw on the fuel filter does not have to be opened.|. Fuel tank Pre-cleaner Fulpump me . Fuel pre-filter . Fuel fine filter . Injection pump . Fuel injector nozzle . Overflow valve @PNATRYNS ‘Benennung / Description / Denomination ‘Datum / Edition / a Fuel system 1212003 Vp Mode! Type ‘Bist Page Feuille Ee Se Pressurized No pressure D904 914/924 D906 /916/ 926 222.1 Fuel system Distributor injection pump ‘The fuel pump 3 draws fuel from tank 1 through the fuel prefitter 2 and pumps it under pressure via the fuel fine fiter 4 to the injection pump 5. ‘The fuel flows under pressure from the injection pump 5 via the injection lines to the fue! injectors 6. From there itis atomized and sprayed into the combustion chamber. ‘The excess fuel from the injection pump 5 and from the fuel injectors 6 is returned to the fuel tank 1 To bleed the fuel syste Proceed as follows, in thst order: 1 Loosen the bleeder screw on the fuel finefilter 4. 2 Loosen the fuel line 7 from the injection pump 5 to the fuel tank 1 on the injection pump. 3 Loosen the union nuts on the injection lines on the fuel injector valves 6, ‘At point 1, 2, actuate the lever on the fue! pump 3 until fuel emerges without air bubbies. Retighten the screws. ‘At point 3, actuate the starter until fuel emerges without air bubbles. Retighten the linesPressurized 1 Fuel tank 2 Fuel pre-filter 3 Fuelpump mms No pressure 4 Fuel fine filter 5 Injection pump 6 Injector nozzle 7 Fuel retum line Typ D904/914/ 924 Mode Model 906 / 916 / 926 ‘Benennung/ Description / Denomination ‘Datum / Edition / Date 42/2003 Fuel system Page Feuille 22423 Fuel pump Installation on in-line injection pumps ‘On engines with in-line infection pumps, a simple fuel pump made by Bosch is installed Depending on the engine model, itis actuated viaa single cam or double cam on the camshaft of the injection pump. (On the version with the single cam, one stroke is actuated per rotation, 2 strokes on the double cam. Function : During the cam stroke, the pump piston 13 with the integrated suction valve 2 is moved by the glide plunger 9 against the force of the spring 7. ‘The suction valve 2 is opened due to the vacuum, which is created in the working chamber, znd fuel flows through the vents in the piston bottom into the working chamber between the suction valve 2 and the pressure valve 6. At the return stroke due to the spring 7, the suction valve 2 closes, the pressure valve 6 is ‘opened and fuel is supplied into the pressure line and on via the fiters to the injection pump. Note: IF the O-ring 10 on the fuel pump leaks, Diese! fue will get into the engine oil via the infection pump!Design 4 Pump housing 2 Suction valve Le 9° 3 Spring plate _ 40 4 O-ring 1 | n 5 Pressure connection = 2————_ | 12 6 Pressure valve 3——~ 13 7 Pressure spring 4 14 8 Spring plate pear ; 9 Plunger a + 10 O-ring se 15 41 Plunger housing 2 ies. 12 O-ring 13 Pump piston 8 14 Spacer 15 Suction connection 4 Working chamber 2 Suction chamber double cam Single cam Cam stroke Spring stroke Tye D904/914/ 924 'Benennung / Description / Denomination Model 906/916 / $26 Datum J Eltion / Date 121 2003 Fuel pump age Feuille23.1 Fuel pump Installation on distributor injection pumps ‘On engines with distributor injection pumps, a membrane fuel pump made by Pierburgis installed, On this version, a cam on the drive gear of the injection pump is actuated, via a drive lever 1 (One stroke is actuated per rotation. Function : During the cam stroke, the drive lever 1 pushes the membrane rod 2 with its fork-like end and thereby the membrane 3 against the spring force downward. This is the suction stroke of the fuel pump. Due to the opening inlet valve 4, the fuel is drawn into the membrane chamber. The outlet valve 6 remains closed. F the drive lever 1 then runs off the cam, the membrane 3 is moved during its upward stroke anly by the force of the spring 5. During this stroke, the fuel is supplied through the opening outlet valve 6 to the injection pump. The inlet valve 4 remains closed The spring force of spring § is designed in such away that the membrane 3 moves only part of the stroke if pressure increases in the supply line, and stops altogether when the maximum static pressure is reached. This protects pump and drive parts from damage due to high pressure. ‘The hand pump device consists of an external manual lever 7, which moves the drive lever 4 when actuated Note It membrane 3 on the fuel pump leaks, Diesel fue! will get into the engine oil via the injection pump drive!Drive lever Membrane rod Membrane Inlet valve Spring Outlet vaive Hand lever Fuel strainer PASaPepe Benennung / Description / yp. Denomination Model 924/926 T-E Datum / Edition / Fuel pump Dato 12200324 Fuel filter Installation on engines with in-line injection pumps On earlier engine models, the fuel fiter was installed as a fuel stage box fiter between the fuel ump and the injection pump. The prefitter 1 had a fiter sensitivity of 50 - 60 jum, the fine filter 2 of 7 - 8 um. Drain plugs (see arrows) are installed on the underside of the fitter. ‘On newer engine models, the prefiter 3 is installed between the fuel tank and the fuel pump and the fine fiter 4 between fuel pump and injection pump. This design protects the fuel pump from wear. ‘The prefiter 3 has a fiter sensitivity of 30 jm, the fine filter 4 of 7 - 8 um, Drain plugs (see arrows) are installed on the underside of the fiter. For maintenance intervals to drain condensation, refer to the Maintenance Schedule. To change the fuel filter For change intervals, see Maintenance Schedule. 13 =Prefiter 24 == Fine filter Remove the fier elements and clean the sealing surface on the filter console Install new filter elements, lubricate the rubber seal ring lightly with oil, and tighten by hand. To bleed the fuel system, see page 22.Stage box filter Tye 9041 914/ 924 Model 0.906 /916 /926 Type Datum /Edtion Date 1212003, Fuel filter Page 4 Feuille 224.1 Fuel filter Installation on engines with distributor injection pumps On engines with distributor injection pumps, a pre- and two fine fier is installed to filter the fuel. The prefiter 1 is installed between the fuel tank and the fine fiers 2 is installed between the fuel pump and the injection pump. The prefiter 1 tas a fiter sensitvty of 30 pm, the tine Miter 2 of 2 pm. The two fine fiters are arranged parallel. ‘The prefiter 1 has a water separator with drain plug (see arrow). The fine fiers 2 has a drain plug (see arrow). For maintenance intervals, see Maintenance Schedule. To change the fuel filter: For change intervals, see Maintenance Schedule. Prefitter: Remove screws, cover 5 and the fiter. Insert new fiter and install cover § with new gasket. Fine filter: ‘Tum the mounting rings 3, 4 to the left and remove the filter elements 2 from the fiter console. Push the mounting rings 3, 4 over the new filter element 2 Install new filter elements 2 on the filter console and turn the mounting rings 3, 4 to the stop. To bleed the fuel system, see page 22.1Flow schematic Benennung / Description / Denomination Typ, D 924/926 T-E At Daten Eton Fuel filter Tat Page 42/2003, Foul ma25 Injection pumps. (On D 904 / 906 engines, in-line injection pumps made by Bosch, pump size ,A" , are installed 1 injection pump | Pump piston | Injection pump Engine RPM ‘Imin size dk regulator, lameter LDA-installation 2mm D904 NA 2000 A 35 RV, D904 TB, 2000 A 95 RSV D904 T 2000. A 10. ROV/LDA D904 T 2000/2100 A a5 RSV/LDA D906 NA. 2000 A 85 RSV, D906 TB. 2000. A 95 RSV D906 T 2000 A 10, RQV/LDA | D906 T 2000. A 35 RSV D906 Ti 2000 A 10, RQV/LDA, Removal: Installation on injection pump drive, page 26 For positioning, see page26. Remove RPM control, shut off device, electical lines, air lines to suction pipe (LDA installation), fuel lines, irjection fines and lube ol line. Remove the mounting screws on the injection pump. Pull the injection pump from the injection pump drive. IF the coupling sleeve 2 ako pulls out, then push itagain onto the drive hub 3. Installation: Install new O-ring 4 and lubricate it lightly with of. Push the injection pump with gear shaft 1 into the coupling sieeve 2 in such a way that the fension pin & in the gear shaft 1 and the bore 6 in hub 3 align, Push the injection pump into the injection pump drive, Install the mounting screws and tighten. Install all parts, which were removed before. Removal: Installation on injection pump drive, page 26.1 For positioning, see page26.1 Remove RPM control, shut off device, electical lines, air lines to suction pipe (LDA installation), fue! lines, injection lines and lube al line. Remove the mounting screws on the injection pump. Pull the injection pump from the injection pump drive. Installation: Install new O-ring 1 and lubricate it ightly with of. Push the injection purnp with ge shaft 2 into the hub 3 that the recess on the gear shaft 2 (missing tooth) and the gap in dre hub 3, which is closed off with tension pin 4 align. Push the injection pump into the injection purnp drive. Install the mounting screws and tighten. install all parts, which wete removed before. Set begin of delivery, seepage 26, 26.1 ‘Add about 1 liter of engine oil to the regulator housing before using the new injection pumpD 904/906 Benennung / Description / Denomination Injection pump Pump size >A< Datum Eaton Bae 12/2003 6 Page Foul25.1 Injection pumps (On engine models D 914/ 916 / 924 / 926, in-line injection pumps made by Bosch, pump size -MW" are installed. Engine models D 924 / 916 are also made with other injection pump sizes. cnet em “iin Injection T Pump piston | Teton pump vane pampsiio ) aiameter | Lpaimtaliton @mm Demat 1800 7 2000 Wai, 70 RSV7LDA Deiat 1800 72000 MW 40 RSV/LDA\ (0924 T-BAZ | 7500/1800 / 2000 MW 70 RSV/ LDA, (0 924 TLEAZ 1800 2000 MW, 10 RSV /LDA DeieT, 1800/2000 / 2700 MW, 10 RSV/LDA\ D967 1800/2000 /2100 MW 10 RSV/LDA\ 0 926 T-EAD 1800 / 2000 MV, 10 RSV/LDA| Removal: Installation on injection pump drive, page 26 For positioning, see page 26 Remove RPM control, shut off device, electrical lines, air lines to suction pipe (LDA installation), fuel lines, injection lines and lube of line. Remove the mounting screws on the injection pump. Pull the injection pump from the injection pump drive. Ifthe coupling sleeve 2 abo pulls out, then push itagain onto the drive hub 3. Note: On 6 cylinder engines, the support from injection pump to crankcase must also be removed. Installation: Install new O-ring 4 and ubricate it lightly with oil Push the injection pump with gear shaft 1 into the coupling sleeve 2in such a way that the tension pin 5 in the gear shaft 1 and the bore 6 in hub 3 align. Push the injection pump into the injection pump drive. Install the mounting ‘screws and tighten Install all parts, which were removed before. Removal: Installation on injection pump drive, page 26.1 For positioning, see page 26.1 Remove RPM control, shut off device, electrical lines, air lines to suction pie (LDA installation), fuel lines, inection lines and lube ol line. Remove the mounting screws on the injection pump. Pull the injection pump from the injection pump drive. Note: (On 6 cylinder engines, the support from injection pump to crankcase must also be removedInstallation: Install and lubricate new O-ring 1. Guide the injection pump with gear shaft 2 into the drive hub 3 that the recess on the gear shaft 2 (missing tooth) aligns with the tooth gap, which is closed with the tension pin 4 in the drive hub 3. Push the injection pump into the injection pump drive. Insert the mounting screws and tighten. Install allremoved parts. ‘Adjust begin of delivery, see page 26, 26.1 Before using the new injection pump, add approx. iter engine oil to the regulator housing D 914/924 onennung / Description / Typ Modet D916 /926 Denomination Datum /Eltion/ Injection pump Page 25.4 Feutlle‘Benennung ! Description / eromination D 914/924 Type D916 /926 ‘Daturn Edition / ‘Dato 12/2003 Injection pump Pump size >MW<25.2 Injection pumps ‘On engine models D £24/ 926, in-line injection pumps made by Bosch, pump size ,P*are installed. Depending on the engine version, injection pumps, size P 3000 or P 7100 are also used Engine models D 924 / 926 are also made with other injection pumps. . injection | pump piston | lnjection pump Engine FPM ‘min pumpsize regulator, sigmetor LDA installation gaa TEAR 1800/2000 P3000 ot REV/LDA D924 TEAS | 18007 190072000] P7100, 12 EDC D926 TT 780072000 P3000 att RSVILDA Dee TT 2100 P7100 12 RQVK7LDA 626 THEAZ 740072000, P3000 ot RSV7UDA D926 TEAS 74007 2100 P70 ot RQV-K7LDA D926 TEAS 7800 P7100 oi DC D926 TEAS 7900 P7100 212 EDC Removal: Installation on injection pump drive, page 26.1 For positioning, see page26.1 Remove RPM control, shut off device, electrical lines, air lines to suction pipe (LDA installation), fuel lines, irection lines and lube ail ine. On Ad engines with EDC regulator, remove the mounting screw for the electric plug on the EDC regulator and pull the lug from the regulator. The injection pump must be without power, turn the ignition oft. Remove the mounting sctews on the injection purp. Pull the injection pump from the injection pump drive. Note (On 6 cylinder engines, the support from injection pump to crankcase must also be removed Installation: Install new O-ring tand lubricate it lightly with al. For lube oil supply on drive side of the injection pump, place a new O-ring with grease in the groove on the injection pump. Push the injection pump with gear shaft 2 into the drive hub S in such a way that the recess on the gear shaft 2 (missing tooth) ard the gap in drive hub 3, which is closed off with tension pin4, align. Install mounting screws and tighten, Install all parts, which were removed before. Set begin of delivery, see page 26.1 ‘Add about 1 liter of enghe oil on into the regulator housing before using the new injection pump. On Aé engines with EDC regulator, add approx. Q1 liter and approx. 0.4 | of engine oll into the injection pump.25.3 Injection pumps On engine models D 924/ 926 T-E At, distributor injection pumps (VE) made by Bosch are installed, injection Engine RPM ‘imin ‘pump __| LDA installation D024 T- EAT 2000 VE D924 T-EAt 2000 VE TDA D926 T-EA1 2000. VE LDA Remov: Installation on injection pump drive, page 26.2 For positioning, see page26.2 Remove the fuel pump RPM control, electical lines, air lines to suction pipe (LDA installation), fuel lines ané injection lines. Remove the mounting screws on the injection pump. Pull the injection pump from the injection pump drive. Installation: Install new O-ring 1 and libricate it lightly with oil Push the injection pump with geer shaft 2 into the drive hub 3 in such a way that the tension pin 4 in the gear shaft 2 and the bore 5 in drive hub 3 align. Push the injection pump into the injection pump dive. Install the mounting screws and tighten Install all parts, which were removed before. Set begin of delivery, see page 26.2 Before using the new injection pump, add about 1/4 liter of fuel on the connection of fuel line and fine filter.Datum /Eattion / Date 1212003 Bononnung / Description / Denomination Injection pump Pump size >VE< Typ Model Type D 924/926 T-EA125.4 Injections pumps ‘On engine models D 924 /926 TI-E AS in — line injection pumps made by Bosch, Contral — sleeve injection pump ( H-RP43) are installed. [Engine RPM Tmin | injection pump size [Pump piston Tinjection pump: L { | diameter @ mm | regulator Doz TEAS | 180071900 | H-RP4S 12 EDC 2000/2100 | - D926 THE AS | 1800/1900 FERPAS @ EDC 2000 12100 - Removal: Installation on injection pump drive, page 26.3 {or positioning, see page 26.3 Remove fuel nes and injection lines Disconnect the electrical plug connection between the cable from the injection pump regulator (EDC) and the cable from the engine control unit. The injection pump may not be energized. Tum the ignition off on the machine. Remove the mounting screws on the injection pump. Pull the injection pump from the injection pump drive. Note: On 6 cylinder engines, the support from injection pump to crankcase must also be removed. Installation: Install new O-ring 1 and lubricate it lightly with oil. For lube oil supply on drive side of the injection pump, place a new O-ring with grease ino the groove on the injection pump. Push the injection pump with gear shaft 2 into the drive hub 3 in such a way that the recess on the gear shaft 2 ( missing tooth) and the gap on drive hub 3, which is closed off with tension pin 4 align. Install mounting screws and tighten, instal all parts, which were removed before. Set begin of delivery, see page 26.3. Before operating a new injection pump, add approx. 0,1 liter engine oil into EDC reguiator and approx. 0,6 iter into the njection pump.1D 924/926 TIE AS26 Injection pump drive, adjust begin of delivery Drive installed on timing case On this drive, in-line injection pumps of pump size ,A" and MW" are installed. ‘The connection of injection pump to drive is made via gear shaft 1 and coupling sleeve 2. Set begin of delivery (FB): For begin of delivery data see Engine Data. Remove screws 7 and push cover 8 from the timing case. Set cylinder 1 to the exact FB mark. Note: ‘The center of the two threaded holes on the inspection oort / flywheel housing are the reference points ‘The flywheel is marked with the OT (upper dead center ) and the 10° to 30° marks. Install a high pressure hand pump or overflow pipe on cylinder 1 of the injection pump. Tum off the starting boost. Release screws 9, tum the drive hub 3 with a commercially available pin spanner approx. 90° to the left (turning direction as seen from the fan side onto the engine). ‘Actuate the hand pump, turn back the drive hub 3to the right until flows from the overfiow pipe in droplets. The FB is set. Tighten screws 9 and check the FB (begin of delivery) again by turing the engine. {Fadjustment is correct, reinstall everything. Turn off the starting boost: Injection pump A“ with RV regulator: Remove the protective cap and push the regulating rod back until the lock engages. Injection pump A“ with RSV regulator: Remove the protective cap and position the regulating rod in such a way, that it emerges about 10 to 12 mm from the end of the thread of the protective cap. Injection pump ,MW* with RSV regulator: Set the shut off lever to shut off. Attach the retaining device, Id. No. 0527462 to the shut off lever and mave the shut off lever bac to the stopof the retaining device to the injection pump. Set the contro! lever to ful load. Injection pump ,,MW"* with RSV regulator and solenoid for release of starting boost: “The solenoid may not be actuated with electrical current. Bring the shut off lever from shut off position to normal positien Set the control lever to ful load. Note: ‘The injection pump and regulator descriptions are noted on the data tag of the injection pump or regulator.Gear shaft 1 8 Cover , z Setpingneoe —§ Stone Settee 4 Orin 10 Gear 17 O-ring - ring 11 O-rings 5 Tension pin 12 Ball bearing & Bore 13 Lock ring 7 Screws 14 Threaded ring YP D 904/914 out D 906/916 Benennung | Description / Datum / Eattion 7 Date 1212003 Injection pump diive Adjust begin of delivery26.1 Injection pump drive, adjust begin of delivery Drive is integrated in timing case In-line injection pumps, sze .A", MW" and .P* are installed on this drive. ‘The injection pump is connected to the drive via the gear shaft 2 and drive hub 3, Set begin of delivery (FB) : For data for begin of delivery, see Engine Data. Remove the screws 5 and push the cover 6 from the timing case, Set cylinder 1 to the exact FE mark. Note: The center of the two threaded holes on the inspection port flywheel housing are reference points. The flywheel is marked with the OT (Oberer Totpunkt = upper dead center) and the 10° to 30° marks. Install a high pressure pump or overflow pipe on gylinder 1 of the injection pump. Turoff the starting boost. Release screws 7, tum the drive hub 3 via the clamp 8 with a commerdally available nut wrench DIN3116-C35 approx. 90° to the left (turning direction as seen from the fan side onto the engine) Actuate the pump, tum the drive hub 3 back to the right until fuel flows from the overfiow pe in droplets. FB is now set. Tighten the screws 7 according to the torque specification and check the FB (begin of delivery) again by turning the engine. F adjustment is correct, reinstall everything, Tightening torque for screws 7: PretorqueNm30 3° 40° Nm 410 Set the begin of delivery (FB) with ,EDC“ (Electronic regulation): For data for begin of delivery, see Engine Data. Remove the plug on the injection pump regulator (EDC) and install ight signal transmitter, I. No. 6004308. Clamp the ground terminal of the light signal transmitter to the engine ground. ‘The injection pump must be without power. Turn the ignition off. Proceed as described above, Set begin of delivery. ‘Tum back the drive hub 3to the right until both lights on the light signal transmitter ligh! up. ‘The FB is now set. Tighten the screws 7 according to the torque specification and check the FB (begin of delivery) again by turning the engine. If adjustment is correct, reinstall everything, ‘Tur off the starting boost: Injection pump .A‘ with RSV-Regulator: see page 26 Injection pump , MW" with RSV-Reguiator and solenoid for release - stating boost: see page 26 Injection pump ,P* with RSV-Regulater is the same as ,MW" injection pump: see page 26 Injection pump ,P* with RSV-Regulatcr and: see page 26 solenoid for release - starting boostfs the same as_,MW'" injection pump Injection pump ,P* with RQV- K-Regulator: ‘The starting boost does rot have to be tured off for setting the begin of delivery. Injection pump ,,P with EDG (Electronic regulation): ‘The starting boost does rot have to be turned off or setting the begin of delivery. Nott Injection pumps and regulator descriptions are neted on the data tag of the injection pump or regulator. Typ 904/914 / 924 Model Mosel 306/916 926 Benennung | Description / Denomination Injection pump drive Adjust begin of delivery 26.1 Feuille10 1 3 2 4 ai 8 O-ring 7 Screws 9 Gear shaft 8 Lock ring 10 Drive hub 9 Gear 14 Tension pin 40 Bearing sleeve 12 Screws 11 Thrust washer 43 Cover 42 O-ring Benennung / scription / Denomination LEBHERR 1D 904/914 /924 Type 1D 906/916 /926 Datum / Edition? Injection pump drive ate p 421 2003, Adjust begin of delivery26.2 Injection pump drive, adjust begin of delivery Drive integrated in timing case Distributor injection pumps (VE) are installed on this drive, ‘The injection pump is connected tothe drive via the gear shaft 2 and drive hub 3. Set begin of delivery (FB) : For data for begin of delivery, see Engine Data. Remove the screws 6 and push the cover 7 from the timing case, Set cylinder 1 to OT (OT = upper dead center) Note: ‘The center of the two threaded holes on the inspection port flywheel housing are reference points, The flywheel is marked with the OT (Oberer Totpunkt = upper dead center) and the 10° to 30° marks. ‘Turn back the engine by 30° against the tuning direction frem the OT. Loosen screws 8 and tighten them again with 30 Nm. Remove the cap on the distributor head of the injection pump and install a test device into the distributor head. Insert the dial gauge and sel under pretension of approx. 1 mm to ,O” and tighten. ‘Tur the engine in turning direction until FB is reached on the test gauge. Loosen the retaining screw on the injection pump and remove the support plate. Tighten the retaining ‘screw with 10 - 15 Nm. Do not tum the engine any more. Loosen screws 8, Tum the engine approx. 30° against the turning direction, then turn the engine in tuming direction until the OT mark is reached. Tighten screws 8 with 30 Nm. Loosen the retaining screw on the injection pump, place a support plate undemeath, and tighten the retaining screw with 10 - 15 Nm. Tighten the screws 8 according b torque specification and check the FB again by turing the engine, If adjustment is correct reinstall everything. re-torque Nm 30 3° 40° Tightening torque for screws Nm 140 Note: The injection pump description is noted on the data tag of the injection pump.1 O-ring 8 Screws 2 Gear shaft 9 Gear 3. Drive hub 10 Locking ring 4 Tension pin 11 Bushing 5 Bore 12 Thrust washers 6 Screws 13 O-ring 7 Cover ‘Benennung /Description / Denomination Typ. LEBHERR i (D924/ 926 T-EA1 Injection pump érive Bat Datum / Edition (Date Adjust begin of delivery Page 12/2003 Page 26.226.3 Injection pump drive, adjust begin of delivery Drive is integrated in timing case In-line injection pump size “H-RP4S" (Control-sieeve injection pump ) are installed on this drive. The injection pump is connected tothe drive via the gear staft 2 and drive hub 3 Set the begin of delivery (FB) with “ EDC” ( Electronic regulation): For data for begin of the delivery, see Engine Data, Remove the screws 5 and push the cover 6 from the timing case. Set cylinder 1 to the exact FBmark. Note: The center of the two threaded holes on the inspection port flywheel! housing are reference poins. The flywheel is markee with the OT (Oberer Totpunkt = upper dead center) and the marks from20° before OT until 10° after OT. Remove the plug on the injection pump regulator (EDC) and install light signal transmitter, Id. No. 6004308. Clamp the ground terminal of the light signal transmitter to the engine ground. The injection pump must be without power. Turn the ignition of. Loosen screws 7, turn left drive hub 3 on screws 8 with a scoket head screw to limitof the screus 7 on the oblong holes (Turning direction as seen from the fan side onto the engine) Slowly tum drive hub 3to the right until both lights on the light signal transmitter light up. The FBis now set. Tighten the screws 7 according to the torque specification and check the FB ( begin of delivery) again by turning the engine. If adjustment is correct, reinstall everything Tightening torque for screws 7: Pretorque Nm 30 Nm61 Tightening torque for screws 8: Pretorque Nm 30 Nm 250 Note: ‘The injection pump and regulator descriptions are marked an the data tag for the injection pumpor the regulator." 12 O-ring Gear shatt Drive hub Tension pin Screws Cover Screws Screws Intermediate flange 10 Gear warannuns 11 Bearing sleeves 42 Thrust washer 13 O-ring 14 Adjusting pin ‘Benennung / Description / Denomination atun J Edition / Date 42/2003 4 Injection pump drive Adjust begin of delivery 13 Nee D904 / 914/924 Tyee 1p 906/916 / 92627 Fuel injectors ‘The fuel injectors are accessible on the upper side of the cylinder heads and are attached with a retainer and two screws. Removal: Remove injection lines and leak oilcollector line. Remove screw 1, remove retainer 2 and spacer sleeve 3 Knock the fuel injectors with the puling device from the cyinder head. Remove the seal 4 from the fue! injector or from the bore in the cylinder head, Installation: ‘Attach new O-ring §. Attach the seal 4 with grease on the fue! injector. Lubricate the fuel injector with grease and push into the bore in the cylinder head. Attach the retainer 2 and spacer sleeve 3. Insert screw 1 and tighten according to torque specification. ‘When tightening, tighten screw 1 on the spacer sleeve 3 fist, then the other screw 1 Tightening torque for screw 1: Nm 23 Install leak oil collector line and injection lines. [ important: On D 904, 906, 914, 816, 926 TI engines, the leak oll connections on the fuel injectors must pont to the flywheel side, on D $24 / 926 T / TI-E engines, to the injection pump side. _D 904 / 906 / 914/916 /926 TI D 924 / 926 TITI-E . Mounting screws . Retainer . Spacer Seal O-ring PPeys Benennung/ Description / Denomination D 9047 914/924 jode!_ D906 / 916 / 926 Datum / Edition? nd Ea Fuel injector 12/2003 2727.1 Fuel injectors Function: “The fuel coming from the injection pump 1 under high pressure via the injection line flows via a rod fiter 2 in the pressure channel 3 and from there to the nozzle seat 4. Due to the high pressure, the nozze needle 5 is lifted and the fuel sprays into the combustion chamber. ‘After a drop of the injection pressute, the spring 5 pushes the nozzle needle 5 back to the nozzk seat 4, ending the injection procedure. ‘The leaking fuel along the nozzle neecle § flows via leak cil connection 7 on the nozzle retainer and through the leak oil line back ta the fuel tank. The injection pressure can be adjusted via shims 8. Fuel injection 1 Engine Nozzle pressure (bar) Injection pump Bosch description =New regulator B = operating pressure 1D 904 NA/TB D906 NA/TB DLLA 142 S 980 N=260% B=252* RSV D904T 906 T/TI DLLA 132 $ 981 N=225% = B=217" RQV D904T D906 T/TI DLA 1928980 | N=260% B=252" Rsv DetaT/Ti D916 T/T DLLA 14281189 | N=225% B=217" RSV D926 TI DLLA 14251189 | N=225* B=217"" RSV/RQV-K D924 T-E(A1, A2) D 926 T-E(A1, A2) DLLA 145 P 632 N= 225 * Be217* RSV (A2) D924 TI-E(A2,A3) | DLLA 145 P 632 N=226% B=217" RSV (A2), D926 TIE (A2,A3) | DLA 145.669 RQV- (A3) D924 THE AG DLLA 145 P 632 D926 TLE A4 DLLA 146 P 669 N=225* B=217" EDC D924 TEAS DLLA 145 P 669 =225% B= 217° EDC D926 TIE AS DLLA 145 P 669 N=225* B=217% EDC ‘Torque specification for union nut 9: D 904, 906, 914, 916, 926 TI = Nm 50° D924/ 926 TLE = Nm 40“?. Injection line . Rod filter Pressure channel |. Noozle seat . Noozle pin Spring . Leak oil connection Shims . Union nut D 904/914 /924 yp Model 9.906 / 916/926 Type ‘Benennung / Description / Denomination ‘Datum / Edition / Date 42/2003 Fuel injector Bratt Page Feuille a28 Engine exhaust The engine exhaust is a closed version. ‘The oil separator can be installed on the exhaust side of the engine in a pipe, depending on the engine ‘model, or cn new versions on the upper side of the timing case. The oil separators come in two sizes. Function of oil separator ,,small version“: ‘The lower section of the oil separator is equipped with a fier section made of stee! wool 1. In the upper section is a membrane 2, which is controlled by a spring 3 (membrane valve). Two bieeder holes 4 in ‘cover 5 are used to regulate the membrane valve. Due to the vacuum pressure of the engine, oll flows. from the crankease to the oll separator, Most of the oil is discharged in the filter 1 and runs back via the valve plunger chamber into the oil pan. The discharge gases mixed with oll - air mixture are retuned via the membrane valve or via the pipeline 6 to the engine and burnt. Check the crankcase vacuum pressure: Pull the dipstick and connect the gauge on the dipstick guide tube. Start the engine and bring to maximum RPM Read the crankcase vacuum pressure on the gauge and compare with test values. Note: ‘The engine must be in horizontal position for the test, it must be at operating temperature and the oil level must be correct Test values: Flow quantity: 754 10 1 /min ‘Vacuum pressure: -25 + 20 mm WS Crankcase vacuum pressure: -30to - 80 mm WS. Removal: Loosen the hose clamps 7 on pipe 6 and push the hose 8 from the oil separator. Remove the retainer 9, loosen the mounting clamp 10 and remove the ol separator. Installation: Place a new O-ring 11 into the oil separator. Push the oll separator onto the pipe. Push hose 8 onto pipe 6 and tighten hose clamps 7. install retainer 9 and tighten mounting clamp 10. Note: ‘A damaged oil separator, for example one with a damaged cover 5, emerging oil vapor on two bleeder bores 4 of the membrane vent is nct functioning properly and must be replaced. Replace the oil separator if the given crankcase vacuum pressure cannot be obtained or once every two years.Oil separator "small version" . Filter section . Membrane Spring Vents Cover . Pipe line . Hose clamps B Hose section 3 a . Retainer 40.Mounting clamp NN, 41.0-ring CONAAaENs Tye D 904/914 /924 Benennung / Description ! Model 906/916 / 926 Type Denomination stun / Eaton Engine exhaust 42/2003 Page Feuille 2828.1 Engine exhaust Function oil separator ,large version“: ‘The lower seotion of the oll separator is equipped with a fiter section made of steel wool 1. In the upper section is a membrane 2, which is contiolled by a spring 3 ( membrane valve). A membrane vent 4 in cover 5 is used to regulate the membrane vaive. Due to the vacuum pressure of the engine, oi flows from the crankcase to the oil separator. Most of the oi is Cischarged in the fiter 1 and runs via pipe 6 and cap 7 back into the oil pan. The discharge ‘gases mixed with oil - airmixture are returned via the membrane valve or via the pipeline 8 to the engine and burnt Check the crankcase vacuum pressure: Pull the dipstick and connect the gauge on the dipstick guide tube. Start the engine and bring to maximum RPM. Read the crankcase vacuum pressure on the gauge and compare with test values. Note: ‘The engine must be in horizontal position for the test, it must be at operating temperature and the oil level must be correct. Test values: Flow quantity, 100+ 201 /min Vacuum pressure: -200 # 20 mm WS Crankcase vacuum pressure: -10 to - 80 mm WS Removal: For installation with pipe ine on valve plunger chamber, see page 28. Loosen the hose clamps on pipe 8 and push the hose 10 from the oil separator. Remove the mounting clamp 11 and remove the oil separator from the timing case. Installation: Place a new O-ring 12 ints the oil separator. Pushthe oil separator onto the fitting in the timing case. Push hose 10 ontopipe 8, attach hose clamps 9 and tighten. Tighten mounting clamp. "1 Note: ‘A damaged oil separator, for example one with a damaged cover 5, emerging oll vapor on two bleeder bores 4 of the membrane vent is not functioning properly and must be replaced. Replace the oil separatorf the given crankcase vacuum pressure cannot be obtained or once every two years.Oil separator “large version" 4. Filter section 2. Membrane 3. Spring 4. Membrane vent 5. Cover 6. Return pipe 7. Cap 8. Pipe line 9. Hose clamps 10.Hose section 11.Mounting clamp 12.0-ring D 914/924 916/926 ‘Benennung / Description / Denomination ‘Datum / Editon / Engine exhaust 12/2003 Feuille29 Fan and flywheel side crankshaft seal Fan-side crankshaft seal ‘The fan-side crankshaft seal ring 1 is installed in a seal ring holder 2. Removal: Remove the screws 3, remove the V-belt 4 and the vibration damper 5. Remove screws 6 and remove hub 7 from the crankshaft. Remove screws 8 and remove the seal ring holder 2 together with the seal ring 1 from the timing case. Note ‘The vibration damper 5 isnot installed on all engine models. Installation: Press the new seal ring 1 into the seal ring holder? to the given dimension. Push the seal ring folder 2 with seal ring 1 and new, lubricated O-ring 9 into the timing case. Insert screws 8 and tighten. Push hub 7 onto the crankshaft, install screws 6 and tighten, see torque specifications, Attach the vibration damper! § and V-bet 4. Install screws 3 and tighten, see torque specifications. Tightening torque for screws 6: Pretorque Nm 30 M12 x 1,5 x 160, 20 45 + 45=90 Nm 100 - 160 = 160 M16 x 1,5 x 160, 51°40 + 30 +30 = 100 Nm 100 ~300= 300 Tightening torque for strews 3: PretorqueNm30 M12 x45 3044 Nm 90 - 140 140 M12. x 45 Nm 70~110= 110 MIG x 1,5 x 160, Nm 300 Note: In case of wear grooves in hub 7, the seal ring 1 can be relocated toward the engine sile in the seal ring holder 2, Flywheel-side crankshaft seal: ‘The flywheel-side crankshaft seal ring 10 is also installed in a seal ring holder 11 Removal: Remove screws 12 on the flywheel 13 and remove the flywheel 13 from the crankshaftand the dowel pin 14. Remove screws 15 and remove the seal ring holder 11 together with seal ring 10 from the fywheel housing‘Datum / Edition / Date 42/2003 installa Press the new seal ring 10 into the seal ring holder 11, Push the seal ring holder 11 wih seal ring 10 and new, lubricated O-ring 16 with the installation sleeve onto the crankshaft. Install screws 15 and tighten, Push the flywheel 13 onto the crankshaft and dowel pin 14, Insert screws 12 and tighten, see torque specifications. Tightening torque for screws 12: Pretorque Nm 30 M14 x 1,5 x50 <° 30+ 35=65 Nm 180-330 = 330 M16 x 1,5 x50 5° 30+ 25 += 55 Nm 180 ~ 330 = 330 Pretorque Nm 90 M16 x 4,5 x 130 5° 30 + 30+ 40 = 100 Nm 180 ~ 330 = 330 Note: In case of wear grooves in the crankshaft, the sed ring 10 can be relocated toward theengine side in the seal ring holder 11 Note: When installing the crankshaft seal rings 1 and 10 fil the gap between the protector and seal lip with grease (Molykote Longterm 2 Plus) Benennung / Deserbtion / Denomination Typ D 904/914/ 924 Model D 906/916 / 926 Type Fan and flywheel side crankshaft seal Blatt mm ®Fan side crankshaft seal Shaft seal ring Seal ring holder Screws for V-belt pulley V-belt pulley Vibration damper Screws for hub Hub Screws for seal ring holder O-ring OCONOMREN= Flywheel side crankshaft seal 10 Shaft seal ring 41 Seal ring holder 42 Screws for flywheel 43 Flywheel 44 Pin 45 Screws for seal ring holder 46 O-ring Typ D 904/914 / 924 Model 306 / 916 / 926 ‘Benennung / Description / Denomination Fanand flywheel side crankshaft seal Datum / Edition Date age 12/2003 Foulllo.30 Hydraulic pump auxiliary drive Installation on timing case below the injection pump, 1500, 1800, 2000, 2100 RPM Engine ‘/min 1914, 2297, 2582, 2679 Auxiliary drive ‘min Permissible continuous output: 27 KW (37 PS) at even operation Note: In case of changes on seties installation, contact the engine manufacturer. Remove Remove the lube oil supply line 1 and remove the screws 2. Remove the intermediate flange 3 from the timing case. Remove the gear 4 from the timing case. Installation: Lubricate and attach new O-ring 5 on the intermeciate flange 5. Push gear 4 into the busting in the timing case insuch a way that the lube oil plug 6 points to the injection pump. Push the intermediate flange 3 onto gear 4 and into the timing case. insert screws 2 and tighten. Install the lube oil supply ine * Important: ‘After every installation or repair on the auxiliary drive, check the axial play when installed, 4 Axial play normal: 0.12 - 0.37 mm Limit value: 055mm30.1 Hydraulic pump auxiliary drive Installation on flywheel housing RPM: Engine ‘min = 1500, 1800, 2000, 2100 Auxiliary drive"Imin = 1794, 2153, 2392, 2512 Permissible continuous autput : 77 kW ( 105 PS) at even operation Note: In case of changes on series installation, contact the engine manufacturer. Removal: Remove oil drain plug on flywheel housing and diain oil. Remove the lube oil supply tube from the crankcase to the auxliary drive. Turn out mounting screws 1 on the auxiliary drive, hold nut Zon. Remove auxilary drive from flywheel housing. Installation: Install new O-rings 3, 4 and lightly grease it, Push auxiliary drive into flywheel housing {assure tooth mesh). Install mountng screws 1, washers and nuts 2 and tighten Install lube oil tube, instal and tighten oil drain plug. Fill approx. 1 liter engine ol through oil filer neck. Note: ‘After installation start engine, turn the engine off and check the engine oil level necessary correct the ai level Important: ‘After every installation or repair, check the axial pay on the auxiliary drive, Axial play normal : 0,05 - 0,25 mm Limit value 0,55 mmxn | D906 / 916 / 926 Hydraulic pump auxiliary drive30.2 Hydraulic pump auxiliary drive Installation on flywheel housing Drive- shift a RPM: Engine ‘/min += 1500, 1800, 2000, 2100 Auxiliary drive ‘Imin = 2228, 2675, 2972, 3120 Permissible continuous output : 192 KW (261 PS) at even operation. Note: In case of changes on sets installation, contact the engine manufacturer. Remove Remove oil drain plug on flywheel housing and drain oil. Remove air pressure lines. Disconnect cable to proximity switch 1. Turn out mounting screws 2 on the auxiliary diive, hold nut 2 on, Remove auxiiary drive from flywheel housing, Installation: Install new O-rings 4, 5 and lightly grease it. Push auxiliary drive into flywheel housing i assure tooth mesh ), Install mounting screws 2, washers and nuts 3 and tighten. Install cable from proximity switch 1 and air pressures lines. Install and tighten oil drain plug. Fill approx. 4 liter engine oll through ol filer neck. Note Ifthe proximity switch 1 isremoved, read just ittothe given measurement after reinstalation, ‘After installation start engine, tur the engine off and check the engine oil level, necessary correct the ol level Tightening torque for sbotted nut 8 : Pretorque Nm 30__ Nm 300 Retainer : Loctite 243 Important: After every installation or repair, check the axial play on the auxiliary drive, Gear side: ‘Axial play normal : 0,05 -0,25 mm Limit value 0,55 mm Power take-off side: Axial play normal: 0,15 - 0,35 mm Limitvalue 0,55 mm4 Proximity switeh 12 Thrust rings 2 Mounting screws 13 Bushings 3 Nuts 14 Connecting flange 4 O-ring 15 Sealing cover 5 O-ring {6 Thrust ring 6 Gear shaft 17 Shaft seal ring 7 Housing 18 Collar bearing 8 Slotted nut 9 Coupling ring 10 Shifting fork 11 Adjusting piston D904 / 914/924 D906 /916 / 826 ‘Banonnung / Description / Denomination Hydraulic pump auxiliary drive Datum /Eaition / Date 42/200330.3 Hydraulic pump auxiliary drive Installation on drive gear box for fan drive RPM: Engine ‘min = 1500, 1800, 2000, 2100 Auxiliary drive = 1850, 2219, 2466, 2589 Permissible continuous output: 29,5 KW ( 40 PS) at even operation. Note: In case of changes on seties installation, contact the engine manufacturer. Removal: Loosen screws 1 and remove it. Remove auxiliary drive from tming case. Installatio Install new O-rings 2, 3 on auxiliary drive and lighty grease it Push auxiliary drive into the drive gear box { assure tooth mesh ) insert and tighten sorews 1 Note: ‘The slotted nut 4 has a lett handed thread Tightening torque for sibtted nut Pretorque Nm 30 Nm 240 Retainer : Loctite 243, Important: After every installation or tepair on the auxiliary drive, check the axial play. ‘Axial play normal: 0,05 - 0,25 mm Limit value: 0,85 mmSSX WN 6 “Uy Hydraulic pump auxiliary drive Feuillo31 Air compressor (On earlier engine versions, the air compressors were installed with air cooled cyinder head Newer versions feature ar compressors with coolant cooled cylinder head, they are connected to the cooling circuit of the engine for cooling. ‘The air compressor is driven via a gear. 1600, 1800, 2000, 2100 RPM: Engine n Yimin 1914, 2297, 2552, 2679 Air compressor n ‘min Removal: Remove the air suction and pressure line on the air compressor head. ir compressor head: 0 = Suction connedion 2 = Pressure connection ‘On coolant cooled air compressors, remove the coolant supply and coolant return tine. Remove th elube oil suppl line. Remove nuts 1, remove spring washers 2 and take the air compressor 3 from the timing case. Remove nut 4 and pull the gear 5 with commercialy available gear puller from the shat. Installation: Push gear 5 onto the shalt, Attach nut 4 and tighten according to torque specification. Place new O-ring 6 with grease into the groove on the air compressor flange. Push the air compressor 3 into the tiring case (note the tooth mesh). Attach spring washers 2 and nuts 1 and tighten, Install the lube oil supply line. Install air lines and on the coolant cooled air compressor - the coolant supply line and the coolant retum line, ‘Add coolant. Torque specification fornut4: M18x15 — M20x1,6 M20x 1,5 Nm 80"" (SW=30mm) (SW = 27 mm) Nm 150 Nm 20032 Starter Depending on the engine model, 4 KW, 5,4 KW, 6,6 KW and 9 KW Starters are installed Removal: Disconnect the battery and remove the electrical ines from the starter. Remove nuts 1 and remove the spring washers 2. ‘Take the starter 3 from stid screws 4 in the flywheel housing. Note On starters, which are sealed towards the flywhed housing, there is an O-ring 5 on thestarter flange Check O-ring § and replace it if necessary. Before installation, lubricate i ightly with grease Installation: Push the starter 3 over the stud screws 4 on the fiywheel housing. Attach spring washers 2 and nuts 1 and tighten. Attach the electrical lines on the starter and attach the battery cable.Air compressor “air cooled” 4. Nuts 2. Spring washers 3. Air compressor 4, Nut 5. Gear 6. O-ring PD 904/914 924 Hodel 908/916 / 926 Datam / Edition / 42/2003,1 Nuts 2. Spring washers Starter 4 Stud screws 8 O-ring Typ D 904/914/ 924 ype, 2906 /916/ 82633 Air conditioner compressor and alternator Upto engine No. 98 01 0814 Note: Screws 1, 3 on tension pulleys 2, 4 are socket head screws up to the above engine Na. Check the V-belt tension: Check by hand: ‘The V-belt 5 is tensioned correctly if can be pushed down on the given test point with a force of 120 N by 13 mm. Check with ,.Krikit 2" tester, Id. No. 8042829; Lower the indicator arm A in the test unit, set the test unit on the given test points, Push the button D evenly at a right angle to the V-belt untilthe spring disengages. Carefully remove the test unit and read the value on the pont of intersection of the .KG” scale and the indicator arm A Compare the test value with the chart V-belt New V-belt Run-in V-belt KG scale KG scale 8 grooves approx. 28 mm wide 50 40-50 Adjustment: Loosen screw 1 and preset the tension pulley 2 with wrench (SW 36) in clockwise direction to 45°, Tighten the screw 1. Loosen screw 3 and turn the tension pulley 4 with wrench (SW 36) in clockwise direction until the correct V-belt tensionis reached. Tighten screw 3 Check the V-belt tension again. Change V-belt: Loosen screws 1, 3 and tum the tension pulley 2, 4 with wrench (SW 36) in counterdockwise direction, Remove the V-belt 5 Place a new V-belt 5 and adjust it. Tighten everything again. Important: Let new V-belt 5 run-in about 15 - 20 minutes. Recheck the tension and retersion, as necessary.Screw Tension pulley Screw Tension pulley V-belt 41 2 3 4 5 ‘Benenaung ! Description / Denomination 12/2003 Air conditioner compressor and alternator Modet D 924/926 Feuille33.1 Air conditioner compressor and alternator From engine No. 98 01 0815 Note: ‘Screws 1, 3 on tension pulleys 2, 4 are socket head screws up to the above engine No. Check the V-belt tension: Check by hand: ‘The V-bett 5 is tensioned correstl if it can be pushed down on the given test point with a force of 120 N by 13 mm. Check with ,Krikit 2" tester, Id. No. 8042829: Lower the indicator arm A in the test unit, set the test unit on the given test points. Push the button D evenly at a right angle to the V-belt 5 until the spring disengages. Carefully remove the test unit and read the value on the point of intersection of the .KG" scale and the indicator arm A. Compare the test value with the chart. V-belt New V-belt Run-in V-belt KG scale KG scale 8 grooves - approx. 28 mm wide 80 40-80 Adjustment: Loosen screw 1 and preset the tension pulley 2 with wrench (SW 36) in counterdockwise direction to 45°. Tighten screw 1. Loosen screw 3 and during the tension pulley 4 with wrench (GW 36) in counterclockwise direction until the correct V-belt tension is reached. Tighten screw 3. Check the V-belt tension again. Change V-bel Loosen screws 1, 3 and turn the tension pulley 2, ¢ with wrench (SW 36) in clockwise direction. Remove the V-belt 5 Place a new V-belt 5 and adjust it. Tighten everything again. Important: Let new V-belt 5 run-in about 15 - 20 minutes. Recheck the tension and retension, as necessary,—, eoerapina ty srrtin - Sas wacarter code . . 3 * | 77 x, ! x pope 1 { |} “450; A 5 —| 1} Screw Tension pulley Screw Tension pulley V-belt anons ‘Benennung ! Description / Denomination 924/926 Type Datum / Elton / Date 12/2003 Air conditioner compressor and alternator Page Feuille 33433.2 Air conditioner compressor and alternator From engine No. 2000 010070 Check the V-belt tension: Check by hand: ‘The V-belt 5 's tensioned correctly if it can be pushed down on the given test point with a force of 120 N by 13 mm. Check with “Krikit2” tester, Id.No. 8042829: Lower the indicator arm A in the test unit, set the test unit on the given test points, Push the button D evenly at a rightangle to the V-belt until the spring disengages. Carefully remove the test unit and read the value on the point of intersection of the ‘KG’ scale and the indicator arm A ‘Compare the test value with the chart. V-belt New V-belt KG scale. | _ Run-in V-belt KG stale ] _ I 8 grooves approx. 28) 50 | mm wide | Adjustment: Loosen screw 1 and turn the tension pulley 2 witha ratchet according to DIN 3122 D 12,5 (‘/.") in counterclockwise direcfon to 45°, Tighten screw 1. Loosen screw 3 and during the tension pulley 4 with a ratchet according to DIN 3122 D 12,5 (Jz!) in counterclockwise direction until the correct V-belt tension is reached. Tighten screw 3. Check the V-belt tension again Change V-belt: Loosen screw 1,3 and tum the tension pulleys 2,4with a ratchet according to DIN 3122 D 12.5 (h') in clockwise direction Remove the V-belt 5 Place a new V-belt 5 and adjust it Tighten everytting again. [important: — I | | Let new V-belt 5 run-in about 15-20 minutes Recheck the tension and refension, as | necessary4 Screw 2 Tension pulley 3 Screw 4 Tension pulley 5 V-belt ‘Benenrung// Description / ination y Denomit ‘Mode! D924 / 926 Datum / Edition / ned Air conditioner compressor and alternator 12/200333.3 Air conditioner compressor and alternator (Dayco-tensioning-device) Note This drive is self-tensioning and therefore maintenance free. The V-belt 2 only has to be checked for wear. To change the V-belt: Insert the ratched according to DIN 3122 D 12,5(‘/. into the square hole on the tensioning device 1. Move the tnsioning device 1 ‘oved back against the spring force in counterclockwise direction to the stop and remove V-belt 2. With the tensioning device 2 moved back, place a new V-belt 2 onto the pulleys of crankshaft, air conditioner compressor 6, alternator § and deflection pulley 4 and retum the tensioning device 1 again to tensioned position. Note: When changing the V-belt 2, check the tension pulley 3 and deflection pulley 4 for easy movement and play. Replace defective tension pulley 3 and deflection pulley 4.4. Tension device 2. V-belt 3. Tension pulley 4, Deflection pulley 8. Pulley-alternator 6. Pulley-air conditioner compressor ‘Benennung / Description / Denomination Mode! D9m/926 Air conditioner compressor and aiternator Datum / Edition / Date 42/200334 Starting aid - flame glow system To improve the starting abilty, a flame glow system or a heating flange (see page 34.3) is installed as a standard installation on all engines. Function-flame glow system: In pre-glow position, the solenoid vaive 7 is opened and at the same time, current flows to the flame glow plug 8. During the starting procedure, Diesel fuel is drawn from the fuel tank 4 via the fuel pre-fiter 5 by the fuel pump 2 and is directed via the fuel fine fier 6 to the injection pump 3. From the injectbn pump 3, fuel reaches the heating coil of the flame glow plug 8 via the opened solenoid vale 7. The passing airflow ignites the fue! and is warmed up before getting into the engine. The engine starts quickerin cold ambient temperatures. Note: if a control unit is installed in the machine, then if takes over the function or the monitoring of the flame glow system in connection with an engine temperature sensor. ‘The control unit is not functioning above an engine cil temperature of + 20°C (68° F) Check: Check the solenoid valve: Remove the fuel line on the flame glow plug 8. On the injection pump 3, set the shutoff lever fo "Stop". Turn the engine with the starter, fuel must flow from the fuel line. Bring the shut off lever on the injection purrp 3 from Stop fo normal position and start the engine, the fud flow on the lines must stop. Note I no fuel emerges when the engine is turned, or ithe fuel flow does not stop when the engine is running, then the solenoid valve 7 must be changed. When changing the valve, make sure to note the flow direction, which is marked with an arrow. Check the flame glow plug: Remove the flame glow plug 8 and connect to the fuel line and electrical line. Set the shut off lever on the injection pump 3 to Stop and pre-glow. The heating coil of the flame glow plug 8 must glow red at the end of the pre-glow period. Tum the engine with the starter, the fuel on the glowing heater coil must evaporate, Note: Ifthe flame glow plug 8 dees not glow red on the heater coil or if no fuel reaches the heater coil when the engine Is turned, then the flame glow plug 8 must be replaced.pianos —— pressurized ---—-— without pressure Fuel tank Fuel pump Injection pump Overflow valve Fuel pre-filter Fuel fine filter Solenoid valve Flame glow plug Suction pipe CONQDaONne D 904/914 /924 ‘Benennung/ Description Denomination Model D906 / 916 / 926 Datum / Edition te ve Starting aid - 12/2003 Flame glow system Page Feullle 3434.1 Starting aid - coolant preheating system In extremely cold temperatures, a retrofit coolant preheating system can be installed on all ‘engines, in addition to the standard flame glow system, or heating flange. Function: The coolant fluid is warmed up by a immersion heater 1 and due to gravity, it will start to circulate in the engine. A preheated engine will start easier. Installation on the engine: Note Depending on the engine model, there might already be a connector closed off with a plug on the cooler plate 2. if no connection is available, then the cooler plate 2 has to be replaced with a plat with a connection for the immersion heater 1. Drain the coolant and remove the plug from the cooler plate 2. Apply sealing compound ‘Omnivisc 1050 to the threads on the reducer fiting 3 and install. Also appiy sealing compound ‘Omnivise 1050 to the threads of the immersion heater 1 and install Connect the electrical comections and add coolant.ow GSS. 1 Immersion heater 2 Cooler piate 3 Reducer fitting ‘Benennung ! Description / Denomination Starting aid - Coolant preheating system ‘sooowi240v_ s000w/120V ye Model D 904/ 914/924 Type 906 / 916/926 oat Page Feutlo aA34.2 Starting aid - oil preheating system In addition to the standard flame glow system or heating flange and the retrofil coolant preheating system, an oilpreheating system can be installed on the engines. Function: ‘The oil preheating systent consists of an oil immersion heater 1 and a thermostat 2. The thermostat 2 opens at approx. 76°C and stops the current supply to the oil immersion heater 1. If the oil temperature drops to approx. 38 °C, the thermostat 2 closes, the current supply is reestablished and the engine oil is warmed up. Due to this regulation, the engine oil is not heated up too much, preventing carbonization Installation on the engine: Replace the standard ol pan 4 (if connections are not available) with an oil pan 4 with connections for the immersion heater 1 and thermostat 2. Apply sealing compound Omnivisc 1050 to the threads of the two reduce’ fittings 3 and install Apply sealing compound also to the threads of the oil immersion heater 1 or the thernostat 2 and install Connect the electrical connections and add engine oil.Montagestelle yon Sitouchhaizer u. Thermostat Thenostat 2 Gtteuehheizer 1 beliebig ROWS V 300Ww!Z30V “Schnitt A-B 4 Immersion oil heater 2 Thermostat 3. Reducer fittings 4 Oil pan Typ D 904/914/924 Mode! Model (D906 / 916/926 ‘enennung / Description / Denomination. Batu Eon Starting ald - aut 4212003 il preheating system: Feetie 34234.3 Starting aid — heating flange To improve the cold start capacty same types of engines are equiped with a heating flange 1 instead of a flame glow system. ‘The heating flange 1 is integrated into the air intake manifold Function: {In position preliminary heating, the heating flange 1 is loaded with current and the heatng coil 2 egin to glow. By starting the engine the intake air cross the healing coil 2 and will be supplied wormed to the engine. ‘The engine can start easly by cold temperatures, Technical data: Nominal voltage: U = 24 Y Nominal power after 50s on 24 V: 1,9 KW #/- 10% Resistance (Ohm): 250 +- 10% by 20” (68°F) Checking: Disconnect the cable on the heating flange 1 ‘Connect on the poles 5 the Ohmmeter or multitester and check the resistance. Ifthe heating element 1 is intact, the resistance must have values shown in the specifiation technical characteristics, otherwise the heating element 1 must be changed. Removal: Disconnect the cable on the heating element 1 Disengage and unscrew the bolts by counter holdng the nuts. Remove the heating element 1 from the sucton pipe (manifold). Clean careful the joint surface. Don't drop part fragments into the suction pipe. Installation: Install heating flange 1 with new gaskets 3, mountthe screws and nuts and tight, Connect the electric cable.Heating flange Heater coil Gasket Earth cable Electric connection Nuts 1 2 3 4 5 6 D 904/914 / 924 Model D906 / 916 / 926 ‘Benennung / Description / Denomination Datum /Eattion / Date 12/2003 Starting aid - Heating flange35 Turbocharger ‘Turbochargers made by Kahnie, Kopp and Kausch (KKK) and Schwitzer are installed on the engines. Turbocharger made by KKK Type = K 27, K 29 Turbocharger made by Sehwitzer Type = S 3A, S 2B 0904 78/T 27,28 D906 T8/T/TI kK27 Dsi4T/T =K27 DeweT =K27,K29 DsieTl 27, K29,S3A D926 TI =K29, S3A D924T/TLE ar D926 T/ TLE K29 Charging system Impulse charge Charging pressure _: 0.6 to 2 bar, depending an engine model Removal and installation: Remove the lube oil supply line and the lube oil return fine. Remove the exhaust line to the muffier and the line from the air filter. Remove the air line to the intake manifold or to the charge air cooler. Remove the screws on the exhaust pipe and remove the turbocharger. To determine the data and bearing plays, see page 35.1, 35.2, 35.3, 35.4, Install in reverse order. Note Before installing the lube oll supply tine, add clean engine oil into the bearing housing.‘Condenser housing ‘Condenser wheel Piston ring Oil deflector Turbine housing Heat guard Piston ring Rotor 1 2 3 4 5 6 7 8 D 904/914 / 924 eet 908/916 / 926 ‘Benennung / Description / Denomination Datum / Ealtion / 12/2003 Turbo charger 36Determination of bearing plays ‘Turbo charger - KKK (Kiinnle, Kopp & Kausch) 1. Axial play measurement + Set the test point of the gauge on the front of the turbine wheel hub. Fig. 1.1 po ‘+ Push the rotor down ard set the test gauge to ,0"! + Push the rotor against the test gauge and note the deflection of the pointer. ‘+ The permissible axial plays are noted on the data 1 page. f 2. Radial play measurement = The determination of the radial play is only nesded for the turbine side. + Sot the test point of the test gauge in the center of y the intake cone of the turbine wheel. w Fig. 2.4,2.2 a4 © Pull the turbine wheel hub with a spring scale down, Test force: 50 N. Set test gauge to "0" '* Pull the turbine wheel hub with a spring scale down. Test force: 50N 4 ad — + Note the deftection ofthe pointer. eh Ve © Repeat this measurement, with the rotor turned by oo «The permissible radial plays are noted on the data page. D 904/ 9141924 D906 / 916/926Data page Turbo charger - KKK (Kahnle, Kopp & Kausch) 4. Tightening torque Nm Sze Irate | Koa | k25 | Kar | koe | K29 Part swiortamm | wemghen 7 self locking | —_ M6 TTighiening ” | momentum | — 12 _ “| sw tor 2mm Warm tohtening a ne ‘memenum — 7 —|{— Thien rreraan + — Sons —}|— tuming angle ‘SW 14mm Warm tattening Me momentum _ Tightening —_ Stes momentum + | SW 15mm ‘Warn toning 72 M7 Ginks) momenta — Tightening —_ momentum + SW 10mm ‘Warm tgtening 2 ms moment 5 — Tightening eee — momentum cal warounira — , Without washer _ _ _ Back wall mounting 6 10 With washer [Condenser housing _ _ | Turbine housing (M 3 ~ = “Turbine housing (8) 20 2. Axial play in mm Size Karte | Kee | Kos | Kav | Kae | 20 ‘max. play 0.10 016 3. Radial play in mm Size [kiarie | koa | k25 | Kar | xa | Wo _] max. play 035 040 043 Typ, D $047 914/924 1916 / 926 yet (D906 Blatt Page 35.2 Feuille ‘Benennung / Deserition / Denomination Datum? Edition / Date Turbo charger 12/2003Determination of bearing plays ‘Turbo charger ~ Schwitzer Axial play measurement: Measuring point Set the test point of the test gauge on the front of the turbine wheel hub. Push the rotor down and set the dial gauge to “O"! Push the rotor against the dial gauge and note the defiecton of the pointer. ‘The permissible axial plays are noted on the data page. Radial play measurement: The radial play needs to be determined only on the condenser side. Set the pointer of the dial gauge in the center of the hex nut of the condenser wheel Pull the condenser whee! hub with a spring scale down. Test force: 50 N. Set the dial gauge to.” Pull the condenser wheel hub with a spring scale up. Test force: 50N. Note the deflection of the pointer. Repeat this test, turn the rotor by 90°. ‘The permissible radial plays are noted on the data page. Typ D 904/914/924 Mode! Model 1D 906/916 / 926 ‘Benennung / Description | Denomination Datum /Eaition / Date 12/2003, Turbo charger Page Feuille 36.3Data page Turbo charger - Schwitzer Axial play in mm Size [s1a| s18| s2a | $28 | s3a | sat | t 1 max. play 014 0.17 | 0.20 Radial play in mm B | S3A | S4T 5 | | size $1a| S1B| S2A | S2i .95 | 0.70 | 0.72 max. play 0.61 | 0.51 | 0.82 Typ D 904/ 914/924 wode! 906/916 / 926 ‘Benennung / Description / Denomination Datum / Edition / Date "21 2003 ‘Turbo charger36 Gear drive (Coolant pump installed on timing case) ‘Turning direction viewed rom fan side onto the engine, I Crankshaft gear Ni Intermediate gear I Camshaft gear Iv Gear- Injection ump drive V Gear- Lube oil pump drive Vi Gear- Lube oil pressure pumo Vil Gear- Lube oil suction pump Vill Gear- Coolant pump (Xk — Gear- Air compressor X Gear- Hydraulic pump drive Important: ‘When working on the gear drive, note the gear markings! Description of gear markings on intermediate gear II: EP = Einspritzpumpe = injection ump KW = Kurbelwelle = crankshaftD 904/914 Model D806 / 916 pe Benennung / Descrition / Denomination Datuin/ Edition / Date 12/2003 Gear drive Bit {coolant pump installed on timing case) Page |36.1 Gear drive {Coolant pump integrated in timing case) ‘Turning direction viewed trom fan side onto the engine. ' Crankshaft gear Ii Intermediate geat MM Camshaft gear 1V Gear Injection pump drive VV Gear- Lube oll pump drive Vi Gear- Lube oll pressure pump Vil Gear- Lube oil suction pump vill Gear- Coolant pump 1X Gear- Air compressor xX Gear- Hydraulic pump drive XI Gear for fan driveon camshaft Xil Gear- Fan drive Xill — Gear- Fan drive Note: ‘The fan drive can differ, depending on the engine mode. Version A: Gear Ill and gear Xil. Version B: Gear Xland gear Xil Gears XI, XII and XIll canbe sized differently, depending on the RPM design. Important: ‘When working on the geer drive, note the gear makings! Description of gear markings on intermediate gear I EP = Einspritzpumpe-= injection pump KW = Kurbelwelle = ciankshaftD 904/914 ‘Mode! D 906/916 ‘Benennung / Description / Denomination atun / Edition / Date 1271200" Gear drive {coolant pump integrated in timing case)37 Maintenance and inspection ‘The Maintenance and inspection chart shows all necessary maintenance tasks. These tasks are described in detail in fhe Operation and Maintenance Manual. ‘Optimum maintenance ensures engine operation without problems and fong service life.| [ [Poss every so0 eaten annua] Work to be carried out ul i Ha [check engine veh [cick cooker leo! io iy [visual inepeatn (contamination, damage) lo iy ior = aca into lo. separdor on fe er ole iy [Ful tank-

You might also like

• The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life

  

  From Everand

  The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life

  Mark Manson

  Rating: 4 out of 5 stars

  4/5 (5814)
• The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are

  

  From Everand

  The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are

  Brene Brown

  Rating: 4 out of 5 stars

  4/5 (1092)
• Never Split the Difference: Negotiating As If Your Life Depended On It

  

  From Everand

  Never Split the Difference: Negotiating As If Your Life Depended On It

  Chris Voss

  Rating: 4.5 out of 5 stars

  4.5/5 (844)
• • Magazines
  • Podcasts
  • Sheet music
• Principles: Life and Work

  

  From Everand

  Principles: Life and Work

  Ray Dalio

  Rating: 4 out of 5 stars

  4/5 (609)
• The Glass Castle: A Memoir

  

  From Everand

  The Glass Castle: A Memoir

  Jeannette Walls

  Rating: 4.5 out of 5 stars

  4.5/5 (1717)
• Grit: The Power of Passion and Perseverance

  

  From Everand

  Grit: The Power of Passion and Perseverance

  Angela Duckworth

  Rating: 4 out of 5 stars

  4/5 (590)
• Sing, Unburied, Sing: A Novel

  

  From Everand

  Sing, Unburied, Sing: A Novel

  Jesmyn Ward

  Rating: 4 out of 5 stars

  4/5 (1104)
• Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race

  

  From Everand

  Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race

  Margot Lee Shetterly

  Rating: 4 out of 5 stars

  4/5 (897)
• Shoe Dog: A Memoir by the Creator of Nike

  

  From Everand

  Shoe Dog: A Memoir by the Creator of Nike

  Phil Knight

  Rating: 4.5 out of 5 stars

  4.5/5 (540)
• The Perks of Being a Wallflower

  

  From Everand

  The Perks of Being a Wallflower

  Stephen Chbosky

  Rating: 4.5 out of 5 stars

  4.5/5 (2104)
• The Hard Thing About Hard Things: Building a Business When There Are No Easy Answers

  

  From Everand

  The Hard Thing About Hard Things: Building a Business When There Are No Easy Answers

  Ben Horowitz

  Rating: 4.5 out of 5 stars

  4.5/5 (348)
• Bad Feminist: Essays

  

  From Everand

  Bad Feminist: Essays

  Roxane Gay

  Rating: 4 out of 5 stars

  4/5 (1018)
• Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future

  

  From Everand

  Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future

  Ashlee Vance

  Rating: 4.5 out of 5 stars

  4.5/5 (474)
• Her Body and Other Parties: Stories

  

  From Everand

  Her Body and Other Parties: Stories

  Carmen Maria Machado

  Rating: 4 out of 5 stars

  4/5 (822)
• The Outsider: A Novel

  

  From Everand

  The Outsider: A Novel

  Stephen King

  Rating: 4 out of 5 stars

  4/5 (1866)
• The Emperor of All Maladies: A Biography of Cancer

  

  From Everand

  The Emperor of All Maladies: A Biography of Cancer

  Siddhartha Mukherjee

  Rating: 4.5 out of 5 stars

  4.5/5 (271)
• The Sympathizer: A Novel (Pulitzer Prize for Fiction)

  

  From Everand

  The Sympathizer: A Novel (Pulitzer Prize for Fiction)

  Viet Thanh Nguyen

  Rating: 4.5 out of 5 stars

  4.5/5 (122)
• Angela's Ashes: A Memoir

  

  From Everand

  Angela's Ashes: A Memoir

  Frank McCourt

  Rating: 4.5 out of 5 stars

  4.5/5 (441)
• Brooklyn: A Novel

  

  From Everand

  Brooklyn: A Novel

  Colm Toibin

  Rating: 3.5 out of 5 stars

  3.5/5 (1947)
• The Little Book of Hygge: Danish Secrets to Happy Living

  

  From Everand

  The Little Book of Hygge: Danish Secrets to Happy Living

  Meik Wiking

  Rating: 3.5 out of 5 stars

  3.5/5 (401)
• A Man Called Ove: A Novel

  

  From Everand

  A Man Called Ove: A Novel

  Fredrik Backman

  Rating: 4.5 out of 5 stars

  4.5/5 (4770)
• Steve Jobs

  

  From Everand

  Steve Jobs

  Walter Isaacson

  Rating: 4.5 out of 5 stars

  4.5/5 (807)
• The World Is Flat 3.0: A Brief History of the Twenty-first Century

  

  From Everand

  The World Is Flat 3.0: A Brief History of the Twenty-first Century

  Thomas L. Friedman

  Rating: 3.5 out of 5 stars

  3.5/5 (2259)
• The Art of Racing in the Rain: A Novel

  

  From Everand

  The Art of Racing in the Rain: A Novel

  Garth Stein

  Rating: 4 out of 5 stars

  4/5 (4203)
• Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America

  

  From Everand

  Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America

  Gilbert King

  Rating: 4.5 out of 5 stars

  4.5/5 (266)
• The Yellow House: A Memoir (2019 National Book Award Winner)

  

  From Everand

  The Yellow House: A Memoir (2019 National Book Award Winner)

  Sarah M. Broom

  Rating: 4 out of 5 stars

  4/5 (98)
• A Tree Grows in Brooklyn

  

  From Everand

  A Tree Grows in Brooklyn

  Betty Smith

  Rating: 4.5 out of 5 stars

  4.5/5 (1929)
• A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story

  

  From Everand

  A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story

  Dave Eggers

  Rating: 3.5 out of 5 stars

  3.5/5 (231)
• Yes Please

  

  From Everand

  Yes Please

  Amy Poehler

  Rating: 4 out of 5 stars

  4/5 (1898)
• Team of Rivals: The Political Genius of Abraham Lincoln

  

  From Everand

  Team of Rivals: The Political Genius of Abraham Lincoln

  Doris Kearns Goodwin

  Rating: 4.5 out of 5 stars

  4.5/5 (234)
• The Woman in Cabin 10

  

  From Everand

  The Woman in Cabin 10

  Ruth Ware

  Rating: 3.5 out of 5 stars

  3.5/5 (2522)
• Fear: Trump in the White House

  

  From Everand

  Fear: Trump in the White House

  Bob Woodward

  Rating: 3.5 out of 5 stars

  3.5/5 (738)
• Wolf Hall: A Novel

  

  From Everand

  Wolf Hall: A Novel

  Hilary Mantel

  Rating: 4 out of 5 stars

  4/5 (3811)
• John Adams

  

  From Everand

  John Adams

  David McCullough

  Rating: 4.5 out of 5 stars

  4.5/5 (2409)
• On Fire: The (Burning) Case for a Green New Deal

  

  From Everand

  On Fire: The (Burning) Case for a Green New Deal

  Naomi Klein

  Rating: 4 out of 5 stars

  4/5 (74)
• The Light Between Oceans: A Novel

  

  From Everand

  The Light Between Oceans: A Novel

  M.L. Stedman

  Rating: 4.5 out of 5 stars

  4.5/5 (789)
• Manhattan Beach: A Novel

  

  From Everand

  Manhattan Beach: A Novel

  Jennifer Egan

  Rating: 3.5 out of 5 stars

  3.5/5 (792)
• The Constant Gardener: A Novel

  

  From Everand

  The Constant Gardener: A Novel

  John le Carré

  Rating: 3.5 out of 5 stars

  3.5/5 (104)
• The Unwinding: An Inner History of the New America

  

  From Everand

  The Unwinding: An Inner History of the New America

  George Packer

  Rating: 4 out of 5 stars

  4/5 (45)
• Rise of ISIS: A Threat We Can't Ignore

  

  From Everand

  Rise of ISIS: A Threat We Can't Ignore

  Jay Sekulow

  Rating: 3.5 out of 5 stars

  3.5/5 (137)
• Little Women

  

  From Everand

  Little Women

  Louisa May Alcott

  Rating: 4 out of 5 stars

  4/5 (104)